Ford - Explorer 2wd - Workshop Manual - 1994 - 1994

Factory Workshop Manual Make Ford Model Explorer 2wd Engine and year V6-245 4.0L (1994) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 111 - 120, ( 112 113 114 115 116 117 118 119 ) > System Information > System Diagnosis Code 111 - 120: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. No DTCs OUTPUT OR DTCs NOT LISTED KOEO self-test ..................................................................................................................................... ............................................................... QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 - Check VREF Voltage At Self-Test Connector KOEO self-test ..................................................................................................................................... ............................................................... QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 - Check VREF Voltage At Self-Test Connector DTC 111 System Pass. DTC 112 Intake Air Temperature sensor circuit below minimum voltage, 254 degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA20 - Induce DTC 118 or 113 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 113 Intake air temperature sensor circuit above maximum voltage/ -4O degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA10 - Induce DTC 117 or 112 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 114 Intake air temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor DTC 116 Engine coolant temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor DTC 117 Engine coolant temperature sensor circuit below minimum voltage 254 degrees F indicated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 111 - 120, ( 112 113 114 115 116 117 118 119 ) > System Information > System Diagnosis > Page 7 KOEO Hard Code ................................................................................................................................ .................................................. Go to DA20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA20 - Induce DTC 118 or 113 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 118 Engine coolant temperature sensor circuit above maximum voltage/ -40 degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA10 - Induce DTC 117 or 112 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 121 Closed throttle voltage higher or lower than expected. Indicates throttle position voltage inconsistent with the mass air flow sensor. KOEO Hard Code ................................................................................................................................ .................................................... Go to DH2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH2 - Check For Stuck Throttle Plate KOER Hard Code ................................................................................................................................ .................................................... Go to DH1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH1 - Check for Other DTCs KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 122 Throttle position sensor circuit below minimum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DH10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH10 - Attempt to Generate DTC 123 or 121 KOEO Memory Code ........................................................................................................................... ................................................. Go to DH94 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH94 - Monitor TP Circuit Under Simulated Road Shock DTC 123 Throttle position sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DH3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH3 - Attempt to Generate DTC 122 KOEO Memory Code ........................................................................................................................... ................................................. Go to DH90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH90 - Monitor TP Circuit Under Simulated Road Shock DTC 124 Throttle position sensor voltage higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 125 Throttle position sensor voltage lower than expected. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 111 - 120, ( 112 113 114 115 116 117 118 119 ) > System Information > System Diagnosis > Page 8 KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 126 Manifold absolute pressure or barometric pressure sensor higher or lower than expected. KOEO Hard Code ................................................................................................................................ ..................................................... Go to DF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF1 KOER Hard Code ................................................................................................................................ ..................................................... Go to DF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF1 KOEO Memory Code ........................................................................................................................... .................................................. Go to DF90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF90 DTC 128 Manifold absolute pressure sensor vacuum hose damaged or disconnected. KOEO Memory Code ........................................................................................................................... .................................................. Go to DF11 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF11 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 121 - 130, ( 122 123 124 125 126 127 128 129 ) > System Information > System Diagnosis > 121-128 Code 121 - 130: Testing and Inspection 121-128 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. No DTCs OUTPUT OR DTCs NOT LISTED KOEO self-test ..................................................................................................................................... ............................................................... QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 - Check VREF Voltage At Self-Test Connector KOEO self-test ..................................................................................................................................... ............................................................... QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 - Check VREF Voltage At Self-Test Connector DTC 111 System Pass. DTC 112 Intake Air Temperature sensor circuit below minimum voltage, 254 degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA20 - Induce DTC 118 or 113 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 113 Intake air temperature sensor circuit above maximum voltage/ -4O degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA10 - Induce DTC 117 or 112 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 114 Intake air temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor DTC 116 Engine coolant temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA1 - Check ECT or IAT Sensor DTC 117 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 121 - 130, ( 122 123 124 125 126 127 128 129 ) > System Information > System Diagnosis > 121-128 > Page 13 Engine coolant temperature sensor circuit below minimum voltage 254 degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA20 - Induce DTC 118 or 113 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 118 Engine coolant temperature sensor circuit above maximum voltage/ -40 degrees F indicated. KOEO Hard Code ................................................................................................................................ .................................................. Go to DA10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA10 - Induce DTC 117 or 112 KOEO Memory Code ........................................................................................................................... .................................................. Go to DA90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA90 - Check Sensor DTC 121 Closed throttle voltage higher or lower than expected. Indicates throttle position voltage inconsistent with the mass air flow sensor. KOEO Hard Code ................................................................................................................................ .................................................... Go to DH2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH2 - Check For Stuck Throttle Plate KOER Hard Code ................................................................................................................................ .................................................... Go to DH1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH1 - Check for Other DTCs KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 122 Throttle position sensor circuit below minimum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DH10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH10 - Attempt to Generate DTC 123 or 121 KOEO Memory Code ........................................................................................................................... ................................................. Go to DH94 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH94 - Monitor TP Circuit Under Simulated Road Shock DTC 123 Throttle position sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DH3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH3 - Attempt to Generate DTC 122 KOEO Memory Code ........................................................................................................................... ................................................. Go to DH90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH90 - Monitor TP Circuit Under Simulated Road Shock DTC 124 Throttle position sensor voltage higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 125 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 121 - 130, ( 122 123 124 125 126 127 128 129 ) > System Information > System Diagnosis > 121-128 > Page 14 Throttle position sensor voltage lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G1 - Check for Idle Air DTCs: Initiate KOER Self-Test DTC 126 Manifold absolute pressure or barometric pressure sensor higher or lower than expected. KOEO Hard Code ................................................................................................................................ ..................................................... Go to DF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF1 KOER Hard Code ................................................................................................................................ ..................................................... Go to DF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF1 KOEO Memory Code ........................................................................................................................... .................................................. Go to DF90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF90 DTC 128 Manifold absolute pressure sensor vacuum hose damaged or disconnected. KOEO Memory Code ........................................................................................................................... .................................................. Go to DF11 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP)/DF11 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 121 - 130, ( 122 123 124 125 126 127 128 129 ) > System Information > System Diagnosis > 121-128 > Page 15 Code 121 - 130: Testing and Inspection 129 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 121 - 130, ( 122 123 124 125 126 127 128 129 ) > System Information > System Diagnosis > 121-128 > Page 16 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 131 - 140, ( 132 133 134 135 136 137 138 139 ) > System Information > System Diagnosis Code 131 - 140: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 131 - 140, ( 132 133 134 135 136 137 138 139 ) > System Information > System Diagnosis > Page 20 Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 141 - 150, ( 142 143 144 145 146 147 148 149 ) > System Information > System Diagnosis Code 141 - 150: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 141 - 150, ( 142 143 144 145 146 147 148 149 ) > System Information > System Diagnosis > Page 24 Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 151 - 160, ( 152 153 154 155 156 157 158 159 ) > System Information > System Diagnosis Code 151 - 160: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 151 - 160, ( 152 153 154 155 156 157 158 159 ) > System Information > System Diagnosis > Page 28 Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 161 - 170, ( 162 163 164 165 166 167 168 169 ) > System Information > System Diagnosis Code 161 - 170: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 161 - 170, ( 162 163 164 165 166 167 168 169 ) > System Information > System Diagnosis > Page 32 Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 171 - 180, ( 172 173 174 175 176 177 178 179 ) > System Information > System Diagnosis > 171 Code 171 - 180: Testing and Inspection 171 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 129 Insufficient manifold absolute pressure sensor or mass airflow sensor change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DC13 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC13 - Air Leak at MAF Sensor DTC 136 Lack of heated oxygen sensor switch during KOER self-test, indicates lean (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 137 Lack of heated oxygen sensor switch during KOER self-test, indicates rich (Bank #2). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 139 No heated oxygen sensor switches detected (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 141 Fuel system indicates lean. KOER Hard Code ................................................................................................................................ .................................................... Go to HB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HB - Flexible Fuel (FF) Control/HB1 - Check For Fuel Diluted Engine Oil DTC 144 No heated oxygen sensor switches detected (bank #1). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 157 Mass air flow sensor circuit below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to DC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC10 - Check For Intermittent Sensor DTC 158 Mass air flow sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................. Go to DC21 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected KOEO Memory Code ........................................................................................................................... .................................................. Go to DC21 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 171 - 180, ( 172 173 174 175 176 177 178 179 ) > System Information > System Diagnosis > 171 > Page 37 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor/DC21 - Rerun Self-Test W/MAF Sensor Disconnected DTC 159 Mass air flow sensor signal higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor KOER Hard Code ................................................................................................................................ .................................................... Go to DC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DC - Mass Air Flow (MAF) Sensor DTC 167 Insufficient throttle position change during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................. Go to DH20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DH - Throttle Position (TP) Sensor/DH20 - Perform Dynamic Response Test At Wide Open Throttle DTC 171 Fuel system at adaptive limits, heated oxygen sensor unable to switch (Bank #1) KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 171 - 180, ( 172 173 174 175 176 177 178 179 ) > System Information > System Diagnosis > 171 > Page 38 Code 171 - 180: Testing and Inspection 172 - 179 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 172 Lack of heated oxygen sensor switches indicates lean (bank # 1). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 173 Lack of heated oxygen sensor switches. Indicates rich (bank #1). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 174 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 175 Fuel system at adaptive limits, heated oxygen sensor unable to switch (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 176 Lack of heated oxygen sensor switches, indicates lean (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 177 Lack of heated oxygen sensor switches, indicates rich (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 178 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 179 Fuel system at lean adaptive limit at part throttle, system rich (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 171 - 180, ( 172 173 174 175 176 177 178 179 ) > System Information > System Diagnosis > 171 > Page 39 KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 181 Fuel system at rich adaptive limit at part throttle, system lean (bank #1). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 181 - 190, ( 182 183 184 185 186 187 188 189 ) > System Information > System Diagnosis > 181 Code 181 - 190: Testing and Inspection 181 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 172 Lack of heated oxygen sensor switches indicates lean (bank # 1). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 173 Lack of heated oxygen sensor switches. Indicates rich (bank #1). KOER Hard Code ................................................................................................................................ ....................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 174 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 175 Fuel system at adaptive limits, heated oxygen sensor unable to switch (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 176 Lack of heated oxygen sensor switches, indicates lean (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 177 Lack of heated oxygen sensor switches, indicates rich (bank #2). KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 178 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H1 - Check For Diluted Engine Oil DTC 179 Fuel system at lean adaptive limit at part throttle, system rich (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 181 - 190, ( 182 183 184 185 186 187 188 189 ) > System Information > System Diagnosis > 181 > Page 44 KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 181 Fuel system at rich adaptive limit at part throttle, system lean (bank #1). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 181 - 190, ( 182 183 184 185 186 187 188 189 ) > System Information > System Diagnosis > 181 > Page 45 Code 181 - 190: Testing and Inspection 184 - 189 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 184 Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 185 Mass air flow lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 186 Injector pulsewidth higher than expected or mass airflow sensor lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 187 Injector pulsewidth lower than expected or Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 188 Fuel system at lean adaptive limit at part throttle, system rich (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 189 Fuel system at rich adaptive limit at part throttle, system lean (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 194 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 195 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 211 Profile ignition pickup circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 181 - 190, ( 182 183 184 185 186 187 188 189 ) > System Information > System Diagnosis > 181 > Page 46 KOEO Memory Code ........................................................................................................................... .................................................... Go to NC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC1 - Continuous Code 211: Erratic Ignition DTC 212 Loss of ignition diagnostic monitor input to powertrain control module or spark output circuit grounded. KOEO Memory Code ........................................................................................................................... .................................................... Go to NC3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC3 - Continuous Code 212: Check For Other EEC Codes DTC 213 Spark output circuit open. KOER Hard Code ................................................................................................................................ ..................................................... Go to PC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/PC - Spark Timing Check -- High Data Rate/PC1 Check Power to PCM DTC 214 Cylinder identification circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 215 Powertrain control module detected coil 1 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 216 Powertrain control module detected coil 2 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 217 Powertrain control module detected coil 3 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 218 Loss of ignition diagnostic monitor signal-left side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 219 Spark timing defaulted to 10 degrees, spark output circuit open. KOEO Memory Code - Go to Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 191 - 200, ( 192 193 194 195 196 197 198 199 ) > System Information > System Diagnosis Code 191 - 200: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 184 Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 185 Mass air flow lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 186 Injector pulsewidth higher than expected or mass airflow sensor lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 187 Injector pulsewidth lower than expected or Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 188 Fuel system at lean adaptive limit at part throttle, system rich (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 189 Fuel system at rich adaptive limit at part throttle, system lean (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 194 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 195 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 211 Profile ignition pickup circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to NC1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 191 - 200, ( 192 193 194 195 196 197 198 199 ) > System Information > System Diagnosis > Page 50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC1 - Continuous Code 211: Erratic Ignition DTC 212 Loss of ignition diagnostic monitor input to powertrain control module or spark output circuit grounded. KOEO Memory Code ........................................................................................................................... .................................................... Go to NC3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC3 - Continuous Code 212: Check For Other EEC Codes DTC 213 Spark output circuit open. KOER Hard Code ................................................................................................................................ ..................................................... Go to PC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/PC - Spark Timing Check -- High Data Rate/PC1 Check Power to PCM DTC 214 Cylinder identification circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 215 Powertrain control module detected coil 1 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 216 Powertrain control module detected coil 2 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 217 Powertrain control module detected coil 3 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 218 Loss of ignition diagnostic monitor signal-left side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 219 Spark timing defaulted to 10 degrees, spark output circuit open. KOEO Memory Code - Go to Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 211 - 220, ( 212 213 214 215 216 217 218 219 ) > System Information > System Diagnosis Code 211 - 220: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 184 Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 185 Mass air flow lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G7 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G7 - Visually Inspect MAF Sensor DTC 186 Injector pulsewidth higher than expected or mass airflow sensor lower than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 187 Injector pulsewidth lower than expected or Mass air flow higher than expected. KOEO Memory Code ........................................................................................................................... ...................................................... Go to G9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/G - In-Range MAF/TPS/Fuel Injector Pulse Width Test/G9 - Visual Vacuum Checks DTC 188 Fuel system at lean adaptive limit at part throttle, system rich (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 189 Fuel system at rich adaptive limit at part throttle, system lean (bank #2). KOEO Memory Code ........................................................................................................................... .................................................... Go to HA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/HA - Adaptive Fuel/HA1 - Check For Other Codes DTC 194 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 195 KOEO Memory Code ........................................................................................................................... ...................................................... Go to H5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control/H5 - Cylinder Balance Diagnostic Test Mode: MFI Engines DTC 211 Profile ignition pickup circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to NC1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 211 - 220, ( 212 213 214 215 216 217 218 219 ) > System Information > System Diagnosis > Page 54 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC1 - Continuous Code 211: Erratic Ignition DTC 212 Loss of ignition diagnostic monitor input to powertrain control module or spark output circuit grounded. KOEO Memory Code ........................................................................................................................... .................................................... Go to NC3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC3 - Continuous Code 212: Check For Other EEC Codes DTC 213 Spark output circuit open. KOER Hard Code ................................................................................................................................ ..................................................... Go to PC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/PC - Spark Timing Check -- High Data Rate/PC1 Check Power to PCM DTC 214 Cylinder identification circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 215 Powertrain control module detected coil 1 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 216 Powertrain control module detected coil 2 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 217 Powertrain control module detected coil 3 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 218 Loss of ignition diagnostic monitor signal-left side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 219 Spark timing defaulted to 10 degrees, spark output circuit open. KOEO Memory Code - Go to Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 221 - 230, ( 222 223 224 225 226 227 228 229 ) > System Information > System Diagnosis Code 221 - 230: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 221 Spark timing error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 222 Loss of ignition diagnostic monitor signal-right side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 223 Loss of dual plug inhibit control. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 224 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 225 Knock not sensed during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................... Go to DG1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DG - Knock Sensor/DG1 - Check Sensor Voltage Cycling DTC 226 Ignition diagnostic monitor signal not received. KOEO Hard Code ................................................................................................................................ .................................................... Go to NC2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC2 - Service Code 226: IDM Circuit Failure DTC 232 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 238 Powertrain control module detected coil 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 241 Ignition control module to powertrain control module ignition diagnostic monitor pulsewidth transmission error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 244 Cylinder Identification circuit fault present when cylinder balance test requested. KOER Hard Code ................................................................................................................................ .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 311 Secondary air injection system inoperative during KOER self-test (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 221 - 230, ( 222 223 224 225 226 227 228 229 ) > System Information > System Diagnosis > Page 58 KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 312 Secondary air injection system misdirected during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 313 Secondary air injection system not bypassed during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 314 Secondary air injection system system inoperative during KOER self-test (bank #2) KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 326 Exhaust gas recirculation valve pressure sensor circuit voltage lower than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 231 - 240, ( 232 233 234 235 236 237 238 239 ) > System Information > System Diagnosis Code 231 - 240: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 221 Spark timing error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 222 Loss of ignition diagnostic monitor signal-right side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 223 Loss of dual plug inhibit control. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 224 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 225 Knock not sensed during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................... Go to DG1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DG - Knock Sensor/DG1 - Check Sensor Voltage Cycling DTC 226 Ignition diagnostic monitor signal not received. KOEO Hard Code ................................................................................................................................ .................................................... Go to NC2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC2 - Service Code 226: IDM Circuit Failure DTC 232 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 238 Powertrain control module detected coil 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 241 Ignition control module to powertrain control module ignition diagnostic monitor pulsewidth transmission error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 244 Cylinder Identification circuit fault present when cylinder balance test requested. KOER Hard Code ................................................................................................................................ .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 311 Secondary air injection system inoperative during KOER self-test (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 231 - 240, ( 232 233 234 235 236 237 238 239 ) > System Information > System Diagnosis > Page 62 KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 312 Secondary air injection system misdirected during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 313 Secondary air injection system not bypassed during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 314 Secondary air injection system system inoperative during KOER self-test (bank #2) KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 326 Exhaust gas recirculation valve pressure sensor circuit voltage lower than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 241 - 250, ( 242 243 244 245 246 247 248 249 ) > System Information > System Diagnosis Code 241 - 250: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 221 Spark timing error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 222 Loss of ignition diagnostic monitor signal-right side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 223 Loss of dual plug inhibit control. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 224 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 225 Knock not sensed during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................... Go to DG1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DG - Knock Sensor/DG1 - Check Sensor Voltage Cycling DTC 226 Ignition diagnostic monitor signal not received. KOEO Hard Code ................................................................................................................................ .................................................... Go to NC2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC2 - Service Code 226: IDM Circuit Failure DTC 232 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 238 Powertrain control module detected coil 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 241 Ignition control module to powertrain control module ignition diagnostic monitor pulsewidth transmission error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 244 Cylinder Identification circuit fault present when cylinder balance test requested. KOER Hard Code ................................................................................................................................ .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 311 Secondary air injection system inoperative during KOER self-test (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 241 - 250, ( 242 243 244 245 246 247 248 249 ) > System Information > System Diagnosis > Page 66 KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 312 Secondary air injection system misdirected during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 313 Secondary air injection system not bypassed during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 314 Secondary air injection system system inoperative during KOER self-test (bank #2) KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 326 Exhaust gas recirculation valve pressure sensor circuit voltage lower than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 311 - 320, ( 312 313 314 315 316 317 318 319 ) > System Information > System Diagnosis Code 311 - 320: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 221 Spark timing error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 222 Loss of ignition diagnostic monitor signal-right side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 223 Loss of dual plug inhibit control. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 224 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 225 Knock not sensed during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................... Go to DG1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DG - Knock Sensor/DG1 - Check Sensor Voltage Cycling DTC 226 Ignition diagnostic monitor signal not received. KOEO Hard Code ................................................................................................................................ .................................................... Go to NC2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC2 - Service Code 226: IDM Circuit Failure DTC 232 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 238 Powertrain control module detected coil 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 241 Ignition control module to powertrain control module ignition diagnostic monitor pulsewidth transmission error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 244 Cylinder Identification circuit fault present when cylinder balance test requested. KOER Hard Code ................................................................................................................................ .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 311 Secondary air injection system inoperative during KOER self-test (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 311 - 320, ( 312 313 314 315 316 317 318 319 ) > System Information > System Diagnosis > Page 70 KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 312 Secondary air injection system misdirected during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 313 Secondary air injection system not bypassed during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 314 Secondary air injection system system inoperative during KOER self-test (bank #2) KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 326 Exhaust gas recirculation valve pressure sensor circuit voltage lower than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 321 - 330, ( 322 323 324 325 326 327 328 329 ) > System Information > System Diagnosis > 326 Code 321 - 330: Testing and Inspection 326 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 221 Spark timing error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 222 Loss of ignition diagnostic monitor signal-right side. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 223 Loss of dual plug inhibit control. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 224 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 225 Knock not sensed during dynamic response test KOER. KOER Hard Code ................................................................................................................................ .................................................... Go to DG1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DG - Knock Sensor/DG1 - Check Sensor Voltage Cycling DTC 226 Ignition diagnostic monitor signal not received. KOEO Hard Code ................................................................................................................................ .................................................... Go to NC2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/NC - Ignition Diagnostic Monitor -- High Data Rate/NC2 - Service Code 226: IDM Circuit Failure DTC 232 Powertrain control module detected coil 1, 2, 3 or 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 238 Powertrain control module detected coil 4 primary circuit failure. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 241 Ignition control module to powertrain control module ignition diagnostic monitor pulsewidth transmission error. KOEO Memory Code - Go to Ignition System / Testing and Inspection. DTC 244 Cylinder Identification circuit fault present when cylinder balance test requested. KOER Hard Code ................................................................................................................................ .................................................... Go to DR1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DR - Cylinder Identification (CID) Sensor/DR1 - Will Engine Start DTC 311 Secondary air injection system inoperative during KOER self-test (bank #1). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 321 - 330, ( 322 323 324 325 326 327 328 329 ) > System Information > System Diagnosis > 326 > Page 75 KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 312 Secondary air injection system misdirected during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 313 Secondary air injection system not bypassed during KOER self-test. KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 314 Secondary air injection system system inoperative during KOER self-test (bank #2) KOER Hard Code ................................................................................................................................ .................................................... Go to KC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC1 Visually Inspect Vacuum Hoses DTC 326 Exhaust gas recirculation valve pressure sensor circuit voltage lower than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 321 - 330, ( 322 323 324 325 326 327 328 329 ) > System Information > System Diagnosis > 326 > Page 76 Code 321 - 330: Testing and Inspection 327 - 328 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 327 Exhaust gas recirculation valve sensor circuit below minimum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL1 - Induce DTC 337 KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 328 Exhaust gas recirculation valve position sensor closed voltage lower than expected. KOEO Hard Code ................................................................................................................................ .................................................. Go to DN25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN25 - Check EVP Sensor and EGR Valve Operation KOER Hard Code ................................................................................................................................ .................................................. Go to DN25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN25 - Check EVP Sensor and EGR Valve Operation KOEO Memory Code ........................................................................................................................... ................................................. Go to DN90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN90 - Check Intermittent Sensor DTC 332 Insufficient exhaust gas recirculation flow detected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL30 - Verify Vacuum Present At EGR Valve KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 334 Exhaust gas recirculation valve position sensor closed voltage higher than expected. KOEO Hard Code ................................................................................................................................ .................................................. Go to DN20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN20 - Check For DTC 558 KOER Hard Code ................................................................................................................................ .................................................. Go to DN20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN20 - Check For DTC 558 KOEO Memory Code ........................................................................................................................... ............................................... Go to DN115 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN115 - Check EGR Vacuum w/Engine Running DTC 335 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 321 - 330, ( 322 323 324 325 326 327 328 329 ) > System Information > System Diagnosis > 326 > Page 77 Exhaust gas recirculation valve pressure sensor voltage higher or lower than expected during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL8 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL8 - Remove Garage Forced Air DTC 336 Exhaust pressure high, exhaust gas recirculation valve pressure sensor voltage higher than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 331 - 340, ( 332 333 334 335 336 337 338 339 ) > System Information > System Diagnosis > 332 - 336 Code 331 - 340: Testing and Inspection 332 - 336 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 327 Exhaust gas recirculation valve sensor circuit below minimum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL1 - Induce DTC 337 KOER Hard Code ................................................................................................................................ ................................................... Go to DL22 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL22 - Check PFE/DPFE Sensor Pressure Input Hose For Blockage KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 328 Exhaust gas recirculation valve position sensor closed voltage lower than expected. KOEO Hard Code ................................................................................................................................ .................................................. Go to DN25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN25 - Check EVP Sensor and EGR Valve Operation KOER Hard Code ................................................................................................................................ .................................................. Go to DN25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN25 - Check EVP Sensor and EGR Valve Operation KOEO Memory Code ........................................................................................................................... ................................................. Go to DN90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN90 - Check Intermittent Sensor DTC 332 Insufficient exhaust gas recirculation flow detected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL30 - Verify Vacuum Present At EGR Valve KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 334 Exhaust gas recirculation valve position sensor closed voltage higher than expected. KOEO Hard Code ................................................................................................................................ .................................................. Go to DN20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN20 - Check For DTC 558 KOER Hard Code ................................................................................................................................ .................................................. Go to DN20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN20 - Check For DTC 558 KOEO Memory Code ........................................................................................................................... ............................................... Go to DN115 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DN - EGR Valve Position Sensor/EGR Vacuum Regulator Solenoid/DN115 - Check EGR Vacuum w/Engine Running DTC 335 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 331 - 340, ( 332 333 334 335 336 337 338 339 ) > System Information > System Diagnosis > 332 - 336 > Page 82 Exhaust gas recirculation valve pressure sensor voltage higher or lower than expected during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL8 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL8 - Remove Garage Forced Air DTC 336 Exhaust pressure high, exhaust gas recirculation valve pressure sensor voltage higher than expected. KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 331 - 340, ( 332 333 334 335 336 337 338 339 ) > System Information > System Diagnosis > 332 - 336 > Page 83 Code 331 - 340: Testing and Inspection 337 - 339 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 337 Exhaust gas recirculation valve sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL5 - Induce DTC 327 KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 338 Engine coolant temperature lower than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA100 - Engine Too Cold DTC 339 Engine coolant temperature higher than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA101 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA101 - Engine Too Hot DTC 341 Octane adjust service pin open. KOEO Hard Code ................................................................................................................................ ..................................................... Go to KP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KP - Octane Adjust/KP1 - Inspect Octane Adjust Inline Connector DTC 381 Frequent A/C clutch cycling. KOEO Memory Code ........................................................................................................................... .................................................. Go to X130 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X130 - Check For Causes of Fast A/C Compressor Cycling DTC 411 Cannot control RPM during KOER self-test low RPM check. KOER Hard Code ................................................................................................................................ ................................................... Go to KE15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE15 Engine RPM Error During Self-Test DTC 412 Cannot control RPM during KOER self-test high RPM check. KOER Hard Code ................................................................................................................................ ..................................................... Go to KE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE1 - Check For RPM Drop Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 331 - 340, ( 332 333 334 335 336 337 338 339 ) > System Information > System Diagnosis > 332 - 336 > Page 84 DTC 415 Idle Air Control system at maximum adaptive lower limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 416 Idle Air Control system at upper adaptive learning limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE35 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 452 Insufficient input from vehicle speed sensor to powertrain control module. KOEO Memory Code ........................................................................................................................... .................................................... Go to DP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) DTC 453 Servo leaking down (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 454 Servo leaking up (KOER lVSC test) Refer to Cruise Control / Testing and Inspection. DTC 455 Insufficient RPM increase (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 456 Insufficient RPM decrease (KOER IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 457 Speed control command switch(s) circuit not functioning (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 458 Speed control command switch(s) stuck/circuit grounded (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 459 Speed control ground circuit open (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 341 - 350, ( 342 343 344 345 346 347 348 349 ) > System Information > System Diagnosis Code 341 - 350: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 337 Exhaust gas recirculation valve sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL5 - Induce DTC 327 KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 338 Engine coolant temperature lower than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA100 - Engine Too Cold DTC 339 Engine coolant temperature higher than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA101 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA101 - Engine Too Hot DTC 341 Octane adjust service pin open. KOEO Hard Code ................................................................................................................................ ..................................................... Go to KP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KP - Octane Adjust/KP1 - Inspect Octane Adjust Inline Connector DTC 381 Frequent A/C clutch cycling. KOEO Memory Code ........................................................................................................................... .................................................. Go to X130 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X130 - Check For Causes of Fast A/C Compressor Cycling DTC 411 Cannot control RPM during KOER self-test low RPM check. KOER Hard Code ................................................................................................................................ ................................................... Go to KE15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE15 Engine RPM Error During Self-Test DTC 412 Cannot control RPM during KOER self-test high RPM check. KOER Hard Code ................................................................................................................................ ..................................................... Go to KE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE1 - Check For RPM Drop DTC 415 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 341 - 350, ( 342 343 344 345 346 347 348 349 ) > System Information > System Diagnosis > Page 88 Idle Air Control system at maximum adaptive lower limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 416 Idle Air Control system at upper adaptive learning limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE35 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 452 Insufficient input from vehicle speed sensor to powertrain control module. KOEO Memory Code ........................................................................................................................... .................................................... Go to DP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) DTC 453 Servo leaking down (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 454 Servo leaking up (KOER lVSC test) Refer to Cruise Control / Testing and Inspection. DTC 455 Insufficient RPM increase (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 456 Insufficient RPM decrease (KOER IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 457 Speed control command switch(s) circuit not functioning (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 458 Speed control command switch(s) stuck/circuit grounded (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 459 Speed control ground circuit open (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 381 - 390, ( 382 383 384 385 386 387 388 389 ) > System Information > System Diagnosis Code 381 - 390: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 337 Exhaust gas recirculation valve sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL5 - Induce DTC 327 KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 338 Engine coolant temperature lower than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA100 - Engine Too Cold DTC 339 Engine coolant temperature higher than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA101 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA101 - Engine Too Hot DTC 341 Octane adjust service pin open. KOEO Hard Code ................................................................................................................................ ..................................................... Go to KP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KP - Octane Adjust/KP1 - Inspect Octane Adjust Inline Connector DTC 381 Frequent A/C clutch cycling. KOEO Memory Code ........................................................................................................................... .................................................. Go to X130 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X130 - Check For Causes of Fast A/C Compressor Cycling DTC 411 Cannot control RPM during KOER self-test low RPM check. KOER Hard Code ................................................................................................................................ ................................................... Go to KE15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE15 Engine RPM Error During Self-Test DTC 412 Cannot control RPM during KOER self-test high RPM check. KOER Hard Code ................................................................................................................................ ..................................................... Go to KE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE1 - Check For RPM Drop DTC 415 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 381 - 390, ( 382 383 384 385 386 387 388 389 ) > System Information > System Diagnosis > Page 92 Idle Air Control system at maximum adaptive lower limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 416 Idle Air Control system at upper adaptive learning limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE35 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 452 Insufficient input from vehicle speed sensor to powertrain control module. KOEO Memory Code ........................................................................................................................... .................................................... Go to DP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) DTC 453 Servo leaking down (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 454 Servo leaking up (KOER lVSC test) Refer to Cruise Control / Testing and Inspection. DTC 455 Insufficient RPM increase (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 456 Insufficient RPM decrease (KOER IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 457 Speed control command switch(s) circuit not functioning (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 458 Speed control command switch(s) stuck/circuit grounded (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 459 Speed control ground circuit open (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 411 - 420, ( 412 413 414 415 416 417 418 419 ) > System Information > System Diagnosis Code 411 - 420: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 337 Exhaust gas recirculation valve sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL5 - Induce DTC 327 KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 338 Engine coolant temperature lower than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA100 - Engine Too Cold DTC 339 Engine coolant temperature higher than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA101 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA101 - Engine Too Hot DTC 341 Octane adjust service pin open. KOEO Hard Code ................................................................................................................................ ..................................................... Go to KP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KP - Octane Adjust/KP1 - Inspect Octane Adjust Inline Connector DTC 381 Frequent A/C clutch cycling. KOEO Memory Code ........................................................................................................................... .................................................. Go to X130 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X130 - Check For Causes of Fast A/C Compressor Cycling DTC 411 Cannot control RPM during KOER self-test low RPM check. KOER Hard Code ................................................................................................................................ ................................................... Go to KE15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE15 Engine RPM Error During Self-Test DTC 412 Cannot control RPM during KOER self-test high RPM check. KOER Hard Code ................................................................................................................................ ..................................................... Go to KE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE1 - Check For RPM Drop DTC 415 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 411 - 420, ( 412 413 414 415 416 417 418 419 ) > System Information > System Diagnosis > Page 96 Idle Air Control system at maximum adaptive lower limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 416 Idle Air Control system at upper adaptive learning limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE35 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 452 Insufficient input from vehicle speed sensor to powertrain control module. KOEO Memory Code ........................................................................................................................... .................................................... Go to DP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) DTC 453 Servo leaking down (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 454 Servo leaking up (KOER lVSC test) Refer to Cruise Control / Testing and Inspection. DTC 455 Insufficient RPM increase (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 456 Insufficient RPM decrease (KOER IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 457 Speed control command switch(s) circuit not functioning (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 458 Speed control command switch(s) stuck/circuit grounded (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 459 Speed control ground circuit open (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 451 - 460, ( 452 453 454 455 456 457 458 459 ) > System Information > System Diagnosis Code 451 - 460: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 337 Exhaust gas recirculation valve sensor circuit above maximum voltage. KOEO Hard Code ................................................................................................................................ .................................................... Go to DL5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL5 - Induce DTC 327 KOER Hard Code ................................................................................................................................ ................................................... Go to DL50 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL50 - Code 336 or 337: Check For EVR Malfunction KOEO Memory Code ........................................................................................................................... .................................................. Go to DL90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL90 - All Continuous Memory EGR DTC: Intermittent Verification DTC 338 Engine coolant temperature lower than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA100 - Engine Too Cold DTC 339 Engine coolant temperature higher than expected (thermostat test). KOEO Memory Code ........................................................................................................................... ................................................ Go to DA101 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DA - Intake Air and Engine Coolant Temperature Sensors/DA101 - Engine Too Hot DTC 341 Octane adjust service pin open. KOEO Hard Code ................................................................................................................................ ..................................................... Go to KP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KP - Octane Adjust/KP1 - Inspect Octane Adjust Inline Connector DTC 381 Frequent A/C clutch cycling. KOEO Memory Code ........................................................................................................................... .................................................. Go to X130 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X130 - Check For Causes of Fast A/C Compressor Cycling DTC 411 Cannot control RPM during KOER self-test low RPM check. KOER Hard Code ................................................................................................................................ ................................................... Go to KE15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE15 Engine RPM Error During Self-Test DTC 412 Cannot control RPM during KOER self-test high RPM check. KOER Hard Code ................................................................................................................................ ..................................................... Go to KE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid/KE1 - Check For RPM Drop DTC 415 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 451 - 460, ( 452 453 454 455 456 457 458 459 ) > System Information > System Diagnosis > Page 100 Idle Air Control system at maximum adaptive lower limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 416 Idle Air Control system at upper adaptive learning limit. KOEO Memory Code ........................................................................................................................... .................................................. Go to KE35 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KE - Idle Air Control Control Solenoid DTC 452 Insufficient input from vehicle speed sensor to powertrain control module. KOEO Memory Code ........................................................................................................................... .................................................... Go to DP1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed Sensor (VSS) DTC 453 Servo leaking down (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 454 Servo leaking up (KOER lVSC test) Refer to Cruise Control / Testing and Inspection. DTC 455 Insufficient RPM increase (KOER IVSC test). Refer to Cruise Control / Testing and Inspection. DTC 456 Insufficient RPM decrease (KOER IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 457 Speed control command switch(s) circuit not functioning (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 458 Speed control command switch(s) stuck/circuit grounded (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. DTC 459 Speed control ground circuit open (KOEO IVSC test) Refer to Cruise Control / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 511 - 520, ( 512 513 514 515 516 517 518 519 ) > System Information > System Diagnosis Code 511 - 520: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 511 Powertrain control module Read Only Memory test failure, KOEO self-test. KOEO Hard Code - Replace Powertrain Control Module. KOER Hard Code - Replace Powertrain Control Module. KOEO Memory Code - Replace Powertrain Control Module. DTC 512 Powertrain control module Keep Alive Memory test failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to QB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QB - Continuous Memory Service Code 15/512/QB1 - Check KAPWR to PCM DTC 513 Powertrain control module internal voltage failure, KOEO self-test. KOEO Hard Code - Replace Powertrain Control Module. KOER Hard Code - Replace Powertrain Control Module. KOEO Memory Code - Replace Powertrain Control Module. DTC 519 Power Steering Pressure switch circuit open during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to FF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FF - Power Steering Pressure (PSP) Switch DTC 521 Power Steering Pressure switch circuit did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ...................................................... Go to FF5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FF - Power Steering Pressure (PSP) Switch/FF5 Verify Operator Interaction DTC 521 DTC 522 Vehicle not in "PARK" or "NEUTRAL" during KOEO or Park/Neutral switch circuit open. KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 525 Indicates vehicle in gear or A/C "ON" during self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification KOEO Memory Code ........................................................................................................................... .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 527 Park/Neutral Position switch circuit open or A/C on KOEO self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 511 - 520, ( 512 513 514 515 516 517 518 519 ) > System Information > System Diagnosis > Page 104 KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 528 Clutch Pedal Position switch circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 521 - 530, ( 522 523 524 525 526 527 528 529 ) > System Information > System Diagnosis > 521 - 528 Code 521 - 530: Testing and Inspection 521 - 528 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 511 Powertrain control module Read Only Memory test failure, KOEO self-test. KOEO Hard Code - Replace Powertrain Control Module. KOER Hard Code - Replace Powertrain Control Module. KOEO Memory Code - Replace Powertrain Control Module. DTC 512 Powertrain control module Keep Alive Memory test failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to QB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QB - Continuous Memory Service Code 15/512/QB1 - Check KAPWR to PCM DTC 513 Powertrain control module internal voltage failure, KOEO self-test. KOEO Hard Code - Replace Powertrain Control Module. KOER Hard Code - Replace Powertrain Control Module. KOEO Memory Code - Replace Powertrain Control Module. DTC 519 Power Steering Pressure switch circuit open during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to FF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FF - Power Steering Pressure (PSP) Switch DTC 521 Power Steering Pressure switch circuit did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ...................................................... Go to FF5 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FF - Power Steering Pressure (PSP) Switch/FF5 Verify Operator Interaction DTC 521 DTC 522 Vehicle not in "PARK" or "NEUTRAL" during KOEO or Park/Neutral switch circuit open. KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 525 Indicates vehicle in gear or A/C "ON" during self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification KOEO Memory Code ........................................................................................................................... .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 527 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 521 - 530, ( 522 523 524 525 526 527 528 529 ) > System Information > System Diagnosis > 521 - 528 > Page 109 Park/Neutral Position switch circuit open or A/C on KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification DTC 528 Clutch Pedal Position switch circuit failure. KOEO Memory Code ........................................................................................................................... .................................................... Go to TA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TA - Park/Neutral Position / Clutch Pedal Position Switches/TA1 - System Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 521 - 530, ( 522 523 524 525 526 527 528 529 ) > System Information > System Diagnosis > 521 - 528 > Page 110 Code 521 - 530: Testing and Inspection 529 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 529 Data Communication Link or Powertrain Control Module circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 532 Cluster Control Assembly circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 533 Data Communication Link or Electronic Instrument Cluster circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 536 Brake On/Off circuit failure or not actuated during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to FD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD1 - Verify Brake Was Pressed KOEO Memory Code ........................................................................................................................... .................................................. Go to FD90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD90 - Check For Proper Stoplamp Switch Installation DTC 538 - Insufficient RPM change during KOER dynamic response test. - Invalid cylinder balance test due to throttle movement during test. - Invalid cylinder balance test due to cylinder identification circuit failure. KOER Hard Code ................................................................................................................................ ...................................................... Go to M1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/M - Dynamic Response Test/M1 - System Failed to Recognize Brief WOT DTC 539 A/C or defrost "ON" during Self-Test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input KOER Hard Code ................................................................................................................................ .................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input DTC 542 Fuel pump secondary circuit failure. KOEO Hard Code ................................................................................................................................ ...................................................... Go to J10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J10 - Does Engine Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 521 - 530, ( 522 523 524 525 526 527 528 529 ) > System Information > System Diagnosis > 521 - 528 > Page 111 Start KOEO Memory Code ........................................................................................................................... ...................................................... Go to J90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J90 - Check EEC-IV Harness DTC 543 Fuel pump secondary circuit failure KOEO Hard Code ................................................................................................................................ ...................................................... Go to J20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit KOEO Memory Code ........................................................................................................................... ...................................................... Go to J93 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J93 - Check For DTC 556 DTC 552 Secondary Air Injection Bypass circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 553 Secondary Air Injection Diverter circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 554 Fuel Pressure Regulator Control circuit failure. KOEO Hard Code ................................................................................................................................ .................................................... Go to KN1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KN - Fuel Pressure Regulator Control Solenoid/KN1 - DTC 554, Enter Output State Diagnostic Test Mode Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 531 - 540, ( 532 533 534 535 536 537 538 539 ) > System Information > System Diagnosis Code 531 - 540: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 529 Data Communication Link or Powertrain Control Module circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 532 Cluster Control Assembly circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 533 Data Communication Link or Electronic Instrument Cluster circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 536 Brake On/Off circuit failure or not actuated during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to FD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD1 - Verify Brake Was Pressed KOEO Memory Code ........................................................................................................................... .................................................. Go to FD90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD90 - Check For Proper Stoplamp Switch Installation DTC 538 - Insufficient RPM change during KOER dynamic response test. - Invalid cylinder balance test due to throttle movement during test. - Invalid cylinder balance test due to cylinder identification circuit failure. KOER Hard Code ................................................................................................................................ ...................................................... Go to M1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/M - Dynamic Response Test/M1 - System Failed to Recognize Brief WOT DTC 539 A/C or defrost "ON" during Self-Test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input KOER Hard Code ................................................................................................................................ .................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input DTC 542 Fuel pump secondary circuit failure. KOEO Hard Code ................................................................................................................................ ...................................................... Go to J10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J10 - Does Engine Start Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 531 - 540, ( 532 533 534 535 536 537 538 539 ) > System Information > System Diagnosis > Page 115 KOEO Memory Code ........................................................................................................................... ...................................................... Go to J90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J90 - Check EEC-IV Harness DTC 543 Fuel pump secondary circuit failure KOEO Hard Code ................................................................................................................................ ...................................................... Go to J20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit KOEO Memory Code ........................................................................................................................... ...................................................... Go to J93 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J93 - Check For DTC 556 DTC 552 Secondary Air Injection Bypass circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 553 Secondary Air Injection Diverter circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 554 Fuel Pressure Regulator Control circuit failure. KOEO Hard Code ................................................................................................................................ .................................................... Go to KN1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KN - Fuel Pressure Regulator Control Solenoid/KN1 - DTC 554, Enter Output State Diagnostic Test Mode Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 541 - 550, ( 542 543 544 545 546 547 548 549 ) > System Information > System Diagnosis Code 541 - 550: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 529 Data Communication Link or Powertrain Control Module circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 532 Cluster Control Assembly circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 533 Data Communication Link or Electronic Instrument Cluster circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 536 Brake On/Off circuit failure or not actuated during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to FD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD1 - Verify Brake Was Pressed KOEO Memory Code ........................................................................................................................... .................................................. Go to FD90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD90 - Check For Proper Stoplamp Switch Installation DTC 538 - Insufficient RPM change during KOER dynamic response test. - Invalid cylinder balance test due to throttle movement during test. - Invalid cylinder balance test due to cylinder identification circuit failure. KOER Hard Code ................................................................................................................................ ...................................................... Go to M1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/M - Dynamic Response Test/M1 - System Failed to Recognize Brief WOT DTC 539 A/C or defrost "ON" during Self-Test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input KOER Hard Code ................................................................................................................................ .................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input DTC 542 Fuel pump secondary circuit failure. KOEO Hard Code ................................................................................................................................ ...................................................... Go to J10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J10 - Does Engine Start Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 541 - 550, ( 542 543 544 545 546 547 548 549 ) > System Information > System Diagnosis > Page 119 KOEO Memory Code ........................................................................................................................... ...................................................... Go to J90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J90 - Check EEC-IV Harness DTC 543 Fuel pump secondary circuit failure KOEO Hard Code ................................................................................................................................ ...................................................... Go to J20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit KOEO Memory Code ........................................................................................................................... ...................................................... Go to J93 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J93 - Check For DTC 556 DTC 552 Secondary Air Injection Bypass circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 553 Secondary Air Injection Diverter circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 554 Fuel Pressure Regulator Control circuit failure. KOEO Hard Code ................................................................................................................................ .................................................... Go to KN1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KN - Fuel Pressure Regulator Control Solenoid/KN1 - DTC 554, Enter Output State Diagnostic Test Mode Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 551 - 560, ( 552 553 554 555 556 557 558 559 ) > System Information > System Diagnosis > 551 - 554 Code 551 - 560: Testing and Inspection 551 - 554 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 529 Data Communication Link or Powertrain Control Module circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 532 Cluster Control Assembly circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 533 Data Communication Link or Electronic Instrument Cluster circuit failure. KOEO Memory Code ........................................................................................................................... ................................................. Go to ML25 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/ML - Self-Test Output/Malfunction Indicator Lamp/ML25 - Continuous Code 529, "Check Engine"/"Check DCL" DTC 536 Brake On/Off circuit failure or not actuated during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to FD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD1 - Verify Brake Was Pressed KOEO Memory Code ........................................................................................................................... .................................................. Go to FD90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/FD - Brake On/Off (BOO) Switch/FD90 - Check For Proper Stoplamp Switch Installation DTC 538 - Insufficient RPM change during KOER dynamic response test. - Invalid cylinder balance test due to throttle movement during test. - Invalid cylinder balance test due to cylinder identification circuit failure. KOER Hard Code ................................................................................................................................ ...................................................... Go to M1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/M - Dynamic Response Test/M1 - System Failed to Recognize Brief WOT DTC 539 A/C or defrost "ON" during Self-Test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input KOER Hard Code ................................................................................................................................ .................................................. Go to KM40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM40 - Check A/C Input DTC 542 Fuel pump secondary circuit failure. KOEO Hard Code ................................................................................................................................ ...................................................... Go to J10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J10 - Does Engine Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 551 - 560, ( 552 553 554 555 556 557 558 559 ) > System Information > System Diagnosis > 551 - 554 > Page 124 Start KOEO Memory Code ........................................................................................................................... ...................................................... Go to J90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J90 - Check EEC-IV Harness DTC 543 Fuel pump secondary circuit failure KOEO Hard Code ................................................................................................................................ ...................................................... Go to J20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit KOEO Memory Code ........................................................................................................................... ...................................................... Go to J93 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J93 - Check For DTC 556 DTC 552 Secondary Air Injection Bypass circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 553 Secondary Air Injection Diverter circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KC9 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KC - Secondary Air Injection Solenoids/KC9 Check Voltage of VPWR Circuit DTC 554 Fuel Pressure Regulator Control circuit failure. KOEO Hard Code ................................................................................................................................ .................................................... Go to KN1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KN - Fuel Pressure Regulator Control Solenoid/KN1 - DTC 554, Enter Output State Diagnostic Test Mode Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 551 - 560, ( 552 553 554 555 556 557 558 559 ) > System Information > System Diagnosis > 551 - 554 > Page 125 Code 551 - 560: Testing and Inspection 556 - 559 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 556 Fuel pump relay primary circuit failure. KOEO Hard Code ................................................................................................................................ ........................................................ Go to J1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J1 - Check For VPWR to Fuel Pump Relay KOEO Memory Code ........................................................................................................................... ...................................................... Go to J95 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J95 - Check EEC-IV Harness DTC 557 Low speed fuel pump primary circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X70 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X70 Code 556 or 557: Check Fuel Pump Relay Coil Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to X115 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X115 Continuous Code 556/557: Check EEC-IV Harness DTC 558 Exhaust gas recirculation valve vacuum regulator circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DL11 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL11 - Measure EVR Solenoid Resistance DTC 559 Air Conditioning On relay circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM60 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM60 - Check For Ignition Run Voltage to A/C Relay DTC 562 Pusher fan control primary circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X10 Check For VPWR to Pusher Fan Control Relay DTC 563 High Fan Control (HFC) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X15 Code 563: Check High Fan Control (HFC) Circuit In CCRM DTC 564 Fan Control (FC) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X20 Does Fan Run With Key On Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 551 - 560, ( 552 553 554 555 556 557 558 559 ) > System Information > System Diagnosis > 551 - 554 > Page 126 DTC 565 Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 566 3-4 shift solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 567 Speed Control Vent (SCVNT) circuit failure. Refer to Ignition System / Testing and Inspection. DTC 568 Speed Control Vacuum (SCVAC) circuit failure. Refer to Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 561 - 570, ( 562 563 564 565 566 567 568 569 ) > System Information > System Diagnosis > 562 - 568 Code 561 - 570: Testing and Inspection 562 - 568 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 556 Fuel pump relay primary circuit failure. KOEO Hard Code ................................................................................................................................ ........................................................ Go to J1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J1 - Check For VPWR to Fuel Pump Relay KOEO Memory Code ........................................................................................................................... ...................................................... Go to J95 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/J - Fuel Pump Circuit/J95 - Check EEC-IV Harness DTC 557 Low speed fuel pump primary circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X70 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X70 Code 556 or 557: Check Fuel Pump Relay Coil Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to X115 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X115 Continuous Code 556/557: Check EEC-IV Harness DTC 558 Exhaust gas recirculation valve vacuum regulator circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DL11 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DL - PFE/DPFE Sensor; EVR Solenoid Testing/DL11 - Measure EVR Solenoid Resistance DTC 559 Air Conditioning On relay circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ................................................. Go to KM60 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KM - WOT A/C Cut-Off (WAC) A/C Demand/KM60 - Check For Ignition Run Voltage to A/C Relay DTC 562 Pusher fan control primary circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X10 Check For VPWR to Pusher Fan Control Relay DTC 563 High Fan Control (HFC) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X15 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X15 Code 563: Check High Fan Control (HFC) Circuit In CCRM DTC 564 Fan Control (FC) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to X20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/X - Constant Control Relay Module (CCRM)/X20 Does Fan Run With Key On Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 561 - 570, ( 562 563 564 565 566 567 568 569 ) > System Information > System Diagnosis > 562 - 568 > Page 131 DTC 565 Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 566 3-4 shift solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 567 Speed Control Vent (SCVNT) circuit failure. Refer to Ignition System / Testing and Inspection. DTC 568 Speed Control Vacuum (SCVAC) circuit failure. Refer to Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 561 - 570, ( 562 563 564 565 566 567 568 569 ) > System Information > System Diagnosis > 562 - 568 > Page 132 Code 561 - 570: Testing and Inspection 569 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 561 - 570, ( 562 563 564 565 566 567 568 569 ) > System Information > System Diagnosis > 562 - 568 > Page 133 A/C clutch circuit open. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 561 - 570, ( 562 563 564 565 566 567 568 569 ) > System Information > System Diagnosis > 562 - 568 > Page 134 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 571 - 580, ( 572 573 574 575 576 577 578 579 ) > System Information > System Diagnosis Code 571 - 580: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 A/C clutch circuit open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 571 - 580, ( 572 573 574 575 576 577 578 579 ) > System Information > System Diagnosis > Page 138 KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 571 - 580, ( 572 573 574 575 576 577 578 579 ) > System Information > System Diagnosis > Page 139 VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 581 - 590, ( 582 583 584 585 586 587 588 589 ) > System Information > System Diagnosis Code 581 - 590: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 A/C clutch circuit open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 581 - 590, ( 582 583 584 585 586 587 588 589 ) > System Information > System Diagnosis > Page 143 KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 581 - 590, ( 582 583 584 585 586 587 588 589 ) > System Information > System Diagnosis > Page 144 VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 591 - 600, ( 592 593 594 595 596 597 598 599 ) > System Information > System Diagnosis Code 591 - 600: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 A/C clutch circuit open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 591 - 600, ( 592 593 594 595 596 597 598 599 ) > System Information > System Diagnosis > Page 148 KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 591 - 600, ( 592 593 594 595 596 597 598 599 ) > System Information > System Diagnosis > Page 149 VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 611 - 620, ( 612 613 614 615 616 617 618 619 ) > System Information > System Diagnosis Code 611 - 620: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 A/C clutch circuit open. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 611 - 620, ( 612 613 614 615 616 617 618 619 ) > System Information > System Diagnosis > Page 153 KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 611 - 620, ( 612 613 614 615 616 617 618 619 ) > System Information > System Diagnosis > Page 154 VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 621 - 630, ( 622 623 624 625 626 627 628 629 ) > System Information > System Diagnosis > 621 - 624 Code 621 - 630: Testing and Inspection 621 - 624 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 569 Auxiliary Canister Purge circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to KD6 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/KD - Canister Purge (CANP) Solenoid/KD6 - Check CANP Solenoid Resistance DTC 571 EGR Atmospheric (EGRA) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 572 EGR Vacuum (EGRV) solenoid circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................. Go to DD20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DD - EGR Position Sensor/Vacuum Solenoid/Atmospheric Solenoid/DD20 - Check EGRV/EGRA Solenoid Resistance DTC 578 A/C pressure sensor circuit shorted. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB40 DTC 579 Insufficient A/C pressure change. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB50 DTC 581 "Power to Fan" circuit over current. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB20 DTC 582 Fan circuit open. KOEO Hard Code ................................................................................................................................ .................................................. Go to XB30 DTC 583 Power to Fuel pump over current. KOEO Memory Code ........................................................................................................................... ................................................ Go to XB135 DTC 584 Variable Control Relay Module (VCRM) power ground circuit open (VCRM Pin 1). KOEO Memory Code ........................................................................................................................... .................................................. Go to XB15 DTC 585 Power to A/C clutch over current KOEO Memory Code ........................................................................................................................... .................................................. Go to XB70 DTC 586 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 621 - 630, ( 622 623 624 625 626 627 628 629 ) > System Information > System Diagnosis > 621 - 624 > Page 159 A/C clutch circuit open. KOEO Memory Code ........................................................................................................................... .................................................. Go to XB80 DTC 587 Variable Control Relay Module communication failure. KOEO Hard Code ................................................................................................................................ ................................................ Go to XB170 KOEO Memory Code ........................................................................................................................... ................................................ Go to XB170 DTC 593 Heated Oxygen Sensor (HO2S) heater circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control KOEO Memory Code ........................................................................................................................... .................................................... Go to H40 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control DTC 617 1-2 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 618 2-3 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 619 3-4 shift error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 621 Shift Solenoid 1 (SS1) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 622 Shift Solenoid 2 (SS2) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 623 Transmission Control Indicator Light circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 624 Electronic Pressure Control circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 621 - 630, ( 622 623 624 625 626 627 628 629 ) > System Information > System Diagnosis > 621 - 624 > Page 160 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 621 - 630, ( 622 623 624 625 626 627 628 629 ) > System Information > System Diagnosis > 621 - 624 > Page 161 Code 621 - 630: Testing and Inspection 625 - 629 NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 625 Electronic Pressure Control driver open in Powertrain Control Module. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 626 Coast Clutch Solenoid (CCS) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 627 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 628 Excessive converter clutch slippage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 629 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 631 Transmission Control Indicator Lamp circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 632 Transmission Control Switch circuit did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 633 4x4L switch closed during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 621 - 630, ( 622 623 624 625 626 627 628 629 ) > System Information > System Diagnosis > 621 - 624 > Page 162 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 634 Transmission Range voltage higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 636 Transmission fluid temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE1 - Sensor Output Outside Test Range KOER Hard Code ................................................................................................................................ ..................................................... Go to TE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE1 - Sensor Output Outside Test Range DTC 637 Transmission fluid temperature sensor circuit above maximum voltage, -40 degrees C (-4O degrees F) indicated, circuit open. KOEO Hard Code ................................................................................................................................ ................................................... Go to TE10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE10 - Attempt To Generate DTC 66 or 638 KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 638 Transmission fluid temperature sensor circuit below minimum voltage, 143 degrees C (29O degrees F) indicated, circuit shorted. KOEO Hard Code ................................................................................................................................ ................................................... Go to TE20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE20 - Attempt To Generate DTC 56 or 637 KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 639 Insufficient input from Transmission Speed Sensor. KOER Hard Code ................................................................................................................................ ..................................................... Go to TF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TF - Turbine Shaft Speed Sensor/Output Shaft Speed Sensor/TF1 - Check TSS/OSS Connector Continuity KOEO Memory Code ........................................................................................................................... ................................................... Go to TF90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TF - Turbine Shaft Speed Sensor/Output Shaft Speed Sensor/TF90 - Complete Transmission Drive Cycle Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 631 - 640, ( 632 633 634 635 636 637 638 639 ) > System Information > System Diagnosis Code 631 - 640: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 625 Electronic Pressure Control driver open in Powertrain Control Module. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 626 Coast Clutch Solenoid (CCS) circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 627 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 628 Excessive converter clutch slippage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 629 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 631 Transmission Control Indicator Lamp circuit failure during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB3 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB3 - Diagnostic Trouble Codes 97, 623 and 631 DTC 632 Transmission Control Switch circuit did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 633 4x4L switch closed during KOEO self-test. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 631 - 640, ( 632 633 634 635 636 637 638 639 ) > System Information > System Diagnosis > Page 166 TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 634 Transmission Range voltage higher or lower than expected. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 636 Transmission fluid temperature higher or lower than expected. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE1 - Sensor Output Outside Test Range KOER Hard Code ................................................................................................................................ ..................................................... Go to TE1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE1 - Sensor Output Outside Test Range DTC 637 Transmission fluid temperature sensor circuit above maximum voltage, -40 degrees C (-4O degrees F) indicated, circuit open. KOEO Hard Code ................................................................................................................................ ................................................... Go to TE10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE10 - Attempt To Generate DTC 66 or 638 KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 638 Transmission fluid temperature sensor circuit below minimum voltage, 143 degrees C (29O degrees F) indicated, circuit shorted. KOEO Hard Code ................................................................................................................................ ................................................... Go to TE20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE20 - Attempt To Generate DTC 56 or 637 KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 639 Insufficient input from Transmission Speed Sensor. KOER Hard Code ................................................................................................................................ ..................................................... Go to TF1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TF - Turbine Shaft Speed Sensor/Output Shaft Speed Sensor/TF1 - Check TSS/OSS Connector Continuity KOEO Memory Code ........................................................................................................................... ................................................... Go to TF90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TF - Turbine Shaft Speed Sensor/Output Shaft Speed Sensor/TF90 - Complete Transmission Drive Cycle Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 641 - 650, ( 642 643 644 645 646 647 648 649 ) > System Information > System Diagnosis Code 641 - 650: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 641 - 650, ( 642 643 644 645 646 647 648 649 ) > System Information > System Diagnosis > Page 170 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 641 - 650, ( 642 643 644 645 646 647 648 649 ) > System Information > System Diagnosis > Page 171 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 651 - 660, ( 652 653 654 655 656 657 658 659 ) > System Information > System Diagnosis Code 651 - 660: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 651 - 660, ( 652 653 654 655 656 657 658 659 ) > System Information > System Diagnosis > Page 175 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 651 - 660, ( 652 653 654 655 656 657 658 659 ) > System Information > System Diagnosis > Page 176 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 661 - 670, ( 662 663 664 665 666 667 668 669 ) > System Information > System Diagnosis Code 661 - 670: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 661 - 670, ( 662 663 664 665 666 667 668 669 ) > System Information > System Diagnosis > Page 180 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 661 - 670, ( 662 663 664 665 666 667 668 669 ) > System Information > System Diagnosis > Page 181 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 671 - 680, ( 672 673 674 675 676 677 678 679 ) > System Information > System Diagnosis Code 671 - 680: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 671 - 680, ( 672 673 674 675 676 677 678 679 ) > System Information > System Diagnosis > Page 185 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 671 - 680, ( 672 673 674 675 676 677 678 679 ) > System Information > System Diagnosis > Page 186 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 691 - 700, ( 692 693 694 695 696 697 698 699 ) > System Information > System Diagnosis Code 691 - 700: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 691 - 700, ( 692 693 694 695 696 697 698 699 ) > System Information > System Diagnosis > Page 190 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 691 - 700, ( 692 693 694 695 696 697 698 699 ) > System Information > System Diagnosis > Page 191 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 991 - 999, ( 992 993 994 995 996 997 998 ) > System Information > System Diagnosis Code 991 - 999: Testing and Inspection NOTE KOEO refers to Key On Engine Off (KOEO) KOER refers to Key On Engine Running (KOER) DTC refers to Diagnostic Trouble Code (DTC) DTCs should be diagnosed in the order they are received. DTC 641 Shift Solenoid 3 circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 643 Torque Converter Clutch circuit failure. KOEO Hard Code ................................................................................................................................ ................................................... Go to TC20 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC20 - Check Solenoid Resistance KOEO Memory Code ........................................................................................................................... .................................................. Go to TC30 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC30 - Visually Check Shift Solenoid Harness DTC 645 Incorrect gear ratio obtained for first gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 646 Incorrect gear ratio obtained for second gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 647 Incorrect gear ratio obtained for third gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 648 Incorrect gear ratio obtained for fourth gear. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 649 Electronic Pressure Control higher or lower than expected. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 651 Electronic Pressure Control circuit failure. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 991 - 999, ( 992 993 994 995 996 997 998 ) > System Information > System Diagnosis > Page 195 Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 652 Torque Converter Clutch solenoid circuit failure. KOEO Hard Code ................................................................................................................................ ..................................................... Go to TC1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC1 - Enter Output State Diagnostic Test Mode DTC 653 Transmission Control Switch did not change states during KOER self-test. KOER Hard Code ................................................................................................................................ ..................................................... Go to TB2 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB2 - Diagnostic Trouble Codes 65, 632 and 653 DTC 654 Transmission Range sensor not indicating "PARK" during KOEO self-test. KOEO Hard Code ................................................................................................................................ .................................................... Go to TD1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TD - Manual Lever Position (MLP) Sensor DTC 656 Torque Converter Clutch continuous slip error. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 657 Transmission over temperature condition occurred. KOEO Memory Code ........................................................................................................................... ................................................ Go to TE100 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TE - Transmission Fluid Temperature (TFT) Sensor/TE100 - Rerun KOEO Self Test DTC 659 High vehicle speed in park indicated. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 667 Transmission Range sensor circuit voltage below minimum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 668 Transmission Range circuit voltage above maximum voltage. KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 675 Transmission Range sensor circuit voltage out of range. Hard fault present, vehicle is in Failure Mode Effects Management (FMEM). KOEO Memory Code ........................................................................................................................... .................................................. Go to TG90 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TG - Electronic Transmission - Continuous Memory Service Codes/TG90 - Perform Drive Cycle Test DTC 676 Go to Transmission and Drivetrain / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 991 - 999, ( 992 993 994 995 996 997 998 ) > System Information > System Diagnosis > Page 196 DTC 677 Go to Transmission and Drivetrain / Testing and Inspection. DTC 691 KOEO Memory Code ........................................................................................................................... .................................................... Go to TB1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TB - 4X4 Low/Transmission Control TCIL-TCS-TCSM/TB1 - Diagnostic Trouble Codes 47, 633 and 691 DTC 998 KOEO Hard Code ................................................................................................................................ ................................................... Go to TC10 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/TC - Transmission Solenoids/TC10 - Check VPWR to Solenoid NO DTCs LISTED Go to .................................................................................................................................................... ................................................................ QA1 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/QA - No Codes/Codes Not Listed/QA1 Check VREF Voltage At Self-Test Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Controller Module: Locations Component Locations The Anti-Theft Controller Module is located at the left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 202 Anti-Theft Controller Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 203 Anti-Theft Controller Module: Description and Operation PURPOSE The Anti-Theft Controller Module controls the vehicle antitheft system through inputs from door, hood, and shock sensors. OPERATION If the anti-theft system is triggered, the starter circuit will be disabled. The module monitors switches located throughout vehicle and if triggered, sounds horn and flashes headlamps and parking lamps at an intermittent rate of 80 cycles per minute. Also disables starting system until anti-theft is disarmed. Senses a 12V signal to arm or disarm the anti-theft system when doors are locked or unlocked by remote transmitter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 207 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 208 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 209 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 214 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 215 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 216 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Power Seat Control Module: Locations Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 220 Power Seat Control Module: Diagrams Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #1 Power Distribution Box The 4WABS Relay #1 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 > Page 226 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #2 Power Distribution Box The 4WABS Relay #2 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 227 4WABS Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 228 4WABS Relay: Description and Operation PURPOSE The system relay has two functions, first when the relay is energized, it supplies power to the six valve solenoids in the valve block assembly and the pump motor relay coil. Second, it supplies ground to the ABS warning light when the relay is de-energized. OPERATION The system relay is controlled by the ECU and is energized when it receives an ignition input signal. LOCATION The system relay is located in the fifth position of the relay block behind the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams > Page 232 Brake Fluid Pump Relay: Description and Operation PURPOSE This relay supplies power to the pump motor. OPERATION The relay coil receives power from the system relay and is controlled by the ECU by providing ground to the coil ground. LOCATION The pump motor relay is located in the fifth position of the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations 4WABS Control Module: Locations All Except Limited Edition And Electronic Group The 4WABS Control Module is located in the engine compartment, behind the driver's side headlamp, mounted on the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 236 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 237 4WABS Control Module: Description and Operation PURPOSE The ECU monitors system operation during normal driving as well as during anti-lock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The ECU continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ECU signals the appropriate solenoid valve in the hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the anti-lock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the ECU. This means that once a code is stored, it will be retained by the ECU even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Refer to Diagnosis and Testing. CONSTRUCTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically. LOCATION The Electronic Control Unit (ECU) is located in the engine compartment behind the driver's side headlamp on a bracket mounted on the surface of the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 238 4WABS Control Module: Service and Repair REMOVAL 1. Disconnect positive battery cable. 4WABS Electronic Control Unit Location 2. Locate ECU on carbon canister bracket attached to LH fender inner sheet metal. Disconnect 40-pin connector from ECU. 3. Remove screw retaining ECU to mounting bracket. 4. Gently slide ECU along bracket to free rivet and remove ECU. INSTALLATION 1. Insert rivet into large hole portion of teardrop. Gently slide ECU along bracket to engage rivet. 2. Install retaining screw and tighten to 7-9 Nm (5.2-6.6 ft lb). 3. Connect 40-pin connector and tighten bolt to 5.2-7.2 Nm (3.9-5.3 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Connect positive battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Speed Control Amplifier Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 243 Cruise Control Module: Service and Repair NOTE: The speed control amplifier is located above the glove box. 1. Open glove compartment and squeeze sides of glove compartment to allow it to rotate down beyond rubber stops. 2. Remove glove compartment courtesy light, then the amplifier and bracket assembly to instrument panel screws. 3. Remove amplifier and bracket assembly from instrument panel. 4. Remove two amplifier screws. 5. Disconnect electrical connectors at amplifier. 6. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Engine > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Box The Blower Motor Relay is mounted in the power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 252 Blower Motor Relay: Description and Operation PURPOSE To provide current to operate the heater-A/C blower motor. OPERATION When the Blower Motor Relay is energized, relay contact closes and completes circuit for blower motor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation Compressor Clutch Relay: Description and Operation PURPOSE When the vehicle operator goes to Wide Open Throttle (WOT), the Wide Open Throttle A/C (WOT A/C) relay opens, suspending A/C operation until normal vehicle operation resumes. This is done to allow maximum power to the drive wheels under heavy acceleration or load. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Chime Module: Locations Component Locations The Warning Buzzer/Chime Module is located in RH side of Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 260 Warning Buzzer/Chime Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Left Brake Lamp Relay: Locations Left Component Locations The LH Stop Relay is located in LH rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Left > Page 269 Brake Lamp Relay: Locations Right Component Locations The RH Stop Relay is located at left rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Right > Page 272 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations All Except Limited Edition And Electronic Group The Daytime Running Lamps (DRL) Module is located at the LH front corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 276 Daytime Running Lamps (DRL) Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations Fog Lamp Relay: Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 280 Component Locations The Fog Lamp Relay is located at the center of the instrument panel, above Warning Buzzer/Chime Module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 281 Fog Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 282 Fog Lamp Relay: Description and Operation OPERATION The Fog Lamp Relay directs power to light the fog lamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Component Locations The Horn Relay is located at the center of Instrument Panel, right of steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 286 Horn Relay: Description and Operation PURPOSE The Horn Relay provides power to horns. OPERATION When the Horn Relay is energized, it directs voltage to sound high and low pitch horns. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Component Locations The Tail Lamp Relay is located at left rear quarter panel. This relay is only used on models equipped with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 290 Tail Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Left Turn Signal Relay: Locations Left Component Locations The LH Turn Signal Relay is located in LH rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Left > Page 295 Turn Signal Relay: Locations Right Component Locations The RH Turn Signal Relay is located at left rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Right > Page 298 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 303 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Component Locations The Powertrain Control Module (PCM) is located under dash, at RH kick panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Diagrams Connector Views Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 311 PCM Connector View Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 312 Powertrain Control Module: Diagrams Terminal Identification Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 313 Powertrain Control Module: Description and Operation PURPOSE The Powertrain Control Module (PCM) monitors the signals from various input sensors and calculates the proper operating strategy for the engine operating conditions. In addition to normal operating strategy the PCM calculates/learns an adaptive strategy that compensates for normal wearing and aging of components. The PCM also provides for self-diagnostic testing. When the ignition is turned on the PCM is continuously checking its inputs and outputs for values out of specification. Any discrepancies are recorded as diagnostic trouble codes. The PCM also provides for operator initiated self-tests. These tests check for specific input values and output states under defined conditions. Note: Incorrect testing conditions and minor procedural deviations often result in false trouble codes and inaccurate information. When initiating self-tests technicians should verify that all required conditions are met. OPERATION The PCM continuously monitors input signals and compares these values to calibration information stored in its memory. The PCM's calibration assembly contains the necessary programming to fine-tune the PCM's engine calibration commands to the vehicle's weight, axle ratio, and transmission application. The calibration assembly is an integral part of the PCM and is not replaceable. The PCM determines the correct operating strategy and makes the necessary corrections to its output signals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure Powertrain Control Module: Reset Procedure KEEP ALIVE MEMORY AND ADAPTIVE STRATEGY The EEC-IV system constantly monitors and adjusts the PCM calibration to correct for normal wear and aging of components. The PCM uses these calibration adjustments to shift fuel delivery calculations and idle speed specifications to compensate for the aging of the vehicle. When an Electronic Engine Controls (EEC) system component is replaced, the Keep Alive Memory (KAM) should be cleared to erase the information stored by the processor from the original component. CLEARING KEEP ALIVE MEMORY To clear the KAM, disconnect the battery negative terminal for five minutes or more (preferably 15 minutes). ADAPTIVE STRATEGY RELEARN PROCEDURE After repairs have been made and the KAM cleared drive the the vehicle for at least ten miles to allow the PCM to relearn the values for optimum performance. NOTE: During the ten mile relearn drive, the vehicle may exhibit some driveability symptoms. These should be eliminated when the KAM has relearned the operating values. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure > Page 316 Powertrain Control Module: Removal and Replacement Powertrain Control Module NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REMOVAL 1. Open hood and disconnect negative battery cable. 2. Remove two screws and right cowl side panel. 3. Disconnect PCM electrical connector. 4. Remove three screws and PCM bracket. 5. Disconnect PCM from connector and remove. INSTALLATION To install PCM, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 320 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 321 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Box The Fuel Pump Relay is located in the power distribution box, on the right side of the engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 329 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 331 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 334 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 335 Fuel Pump Relay: Description and Operation OPERATION When the ignition switch is turned ON, the Electronic Engine Control (EEC) power relay is energized, providing power to the fuel pump relay for 1 to 2 seconds through the Powertrain Control Module (PCM) and an Inertia Fuel Shutoff (IFS) switch. Fuel pump power is provided through the fuel pump relay contacts, if the PCM does not receive an ignition signal within approximately one second after the ignition switch is turned to the "ON" position. A timer circuit in the PCM will open the ground circuit to the fuel pump relay, causing the fuel pump relay contacts to OPEN. This action stops the power supply to the fuel pump. When the ignition switch is turned to the "START" position, the PCM closes the ground circuit to the fuel pump relay, resuming operation of the fuel pump. After the ignition switch is returned to the "ON" position, power to the fuel pump is supplied through the fuel pump relay. The PCM monitors engine speed and opens the fuel pump relay ground circuit if the engine speed drops below 120 rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 339 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 340 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Ignition Control Module: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 346 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 347 Ignition Control Module: Technical Service Bulletins Ignition Control Module - Connector Update Article No. 94-7-8 WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR - FORMERLY CALLED ELECTRONIC DISTRIBUTORLESS IGNITION SYSTEM (EDIS) CONNECTOR - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, GRAND MARQUIS, MARK VIII, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Beginning 1/3/94 revised design ICM connectors are being used after the old style connectors are exhausted. The revised connector has a new seal and new design for better retention. Although the connectors are interchangeable, they pull apart differently. ACTION: If service is required, be aware of the new design when taking the ICM connector apart. ^ The previous style connector had a split beam that had to be pushed "down" while the connector was being pulled off. The word "PUSH" is embossed on the end of the split beam, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 348 ^ The revised style connector has a beam (not split) that must be pried "up", and then pulled off, Figure 2. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 349 Ignition Control Module: Specifications TIGHTENING SPECIFICATIONS ICM mounting screw ............................................................................................................................ ................................... 27-35 lb. in. (3-4 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 350 Ignition Control Module: Locations IGNITION CONTROL MODULE (ICM) LOCATION On RH front corner of engine compartment, left of headlamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 351 Ignition Control Module (ICM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 352 Ignition Control Module: Description and Operation EDIS Module PURPOSE The Electronic Distributorless Ignition System (EI), formerly (EDIS)module's primary function is to deliver full energy spark at a crank angle targeted by the Powertrain Control Module (PCM) and to provide the PCM with crankshaft position information. DESCRIPTION The EI control module is a twelve pin custom microprocessor-based thick film module. Although each engine is very different in size and structure, ICM's for each engine are very similar. With the exception of some pin assignments, basic operation of the EI systems for the different engines is identical. OPERATION The EI control module (ICM) receives input from the Variable Reluctance Sensor (VRS) style Crankshaft Position (CKP) Sensor in order to identify the passing of the missing tooth on the VRS trigger wheel. Synchronization The module is said to be "synchronized" when the missing tooth is found. Synchronization is essential to the ICM in order to track the angular position of the crankshaft relative to a fixed reference and when it should fire the proper coil. Profile Ignition Pickup Profile Ignition Pickup (PIP) output is synthesized by the ICM using input from the VRS signal. The PIP signal generated by the ICM indicates engine speed and crankshaft position to the PCM. The PIP signal is used by the PCM so that it can enable fuel and spark functions and generate a Spark Angle Word (SAW) signal. Spark Angle Word The SAW signal provides spark targeting information to the ICM. By decoding the SAW signal and using the information it receives from the VRS, the ICM turns the coils on and off at correct times and in proper sequence. The EI system operates at a high data rate so it can fire sparks more accurately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 353 Ignition Control Module: Service and Repair Ignition Module REMOVAL 1. Disconnect both battery cables, then remove the battery from the vehicle. 2. Disconnect the electrical connector from the ignition module. NOTE: To disconnect the module connector, push on the connector where it says PUSH, then slide the connector from the module. 3. Remove the ignition module retaining bolt and remove the module by sliding the assembly up until it is released from the teardrop shaped hole in the sheet metal. INSTALLATION 1. Place the module on the sheet metal so the retaining rivet passes through the hole, then slide the module down into position. 2. Install the retaining bolt bolt, torquing to 22-31 lb-in (2.2-3.5 Nm). 3. Connect the electrical connector to the module. 4. Install the battery and cables. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations All Except Limited Edition And Electronic Group The Starter Relay is located at RH front of engine compartment, at fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views Power Window Control Module: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 368 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 369 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 370 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 371 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 372 Power Window Control Module: Locations One Touch Down Power Window Module Component Locations The One-Touch Module is located in LF door panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Page 373 One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 381 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch Power Door Lock Switch: Diagrams Driver's Master Switch Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 386 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 387 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 388 Power Door Lock Switch: Diagrams Passenger Side Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 389 Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 390 Power Door Lock Switch: Description and Operation OPERATION The Door Lock Switch controls a bi-directional motor by supplying a momentary ground or power to either side of motor depending on position of switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Recalls for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: Recalls Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: All Technical Service Bulletins Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 404 Power Mirror Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 405 Power Mirror Switch: Description and Operation PURPOSE The Power Mirror Switch enables the operator to control the movement of the outside mirrors in either vertical or horizontal directions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Memory Seat Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Page 409 Seat Memory Switch: Description and Operation PURPOSE The Memory Seat Switch is used to recall one of two previously recorded seat positions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams Acceleration Sensor: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams > Page 414 Acceleration Sensor: Description and Operation PURPOSE The G-switch detects and indicates to the anti-lock brake control module whether or not the vehicle is moving. OPERATION The G-switch is used on 4x4 vehicles only. When driven in the 4-wheel drive mode all four wheels are mechanically linked and a situation could arise in which one wheel locks up and causes all four wheels to lock up and skid. The speed sensors would indicate the vehicle speed as zero. Without the G-switch, the anti-lock brake control module (2B373) would have no data to compare and would react as if the vehicle were stopped when in fact it is moving. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the antilock brake system and illuminate the antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 419 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The fluid level indicator is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. CONSTRUCTION It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front Axle Sensor: Diagrams Front Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front > Page 427 Axle Sensor: Diagrams Rear Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Page 428 Axle Sensor: Description and Operation PURPOSE The anti-lock brake system uses three sets of variable-reluctance sensors and toothed speed sensor rings to determine the rotational speed of each wheel. OPERATION The sensors operate on magnetic induction principle. As the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the ECU through a twisted-pair wire cable and wiring harness. LOCATION The front sensors are attached to the suspension knuckles, and the speed indicator rings are pressed onto the backside of the rotor. The rear sensor is bolted into the rear axle housing and the rear speed sensor ring is pressed onto the rear axle carrier assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring Axle Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. NOTE: Discard speed sensor ring after removal. Do not reuse old ring. Speed Sensor Ring Removal 4. Using a 3-jaw puller, remove indicator ring from hub. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 431 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 79mm (3.1 in) ID and 96mm (3.8 in) OD, press the ring onto the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear NOTE: To service the speed sensor ring, the differential case must be removed from the axle housing. REMOVAL 1. Remove the bolts retaining the ring gear to the differential case. Remove the ring gear by striking at alternate holes around the gear. CAUTION: Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock brake sensor ring teeth while handling or during assembly. NOTE: ^ Before removing ring gear inspect it and determine if ring runout check is necessary. ^ Do not remove anti-lock speed sensor ring unless replacement is required. It does not have to be removed for ring gear replacement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 432 2. If replacement is required remove the anti-lock brake sensor ring by tapping with a soft-faced hammer. Discard the anti-lock speed sensor ring. CAUTION: The anti-lock speed sensor ring must be discarded upon removal. If removed, a new anti-lock brake sensor ring must be installed. INSTALLATION 1. Position the ring gear and anti-lock speed sensor ring on the differential case. The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case as shown. Start two ring gear retaining bolts through the differential case into the ring gear to make sure case-to-ring gear bolt hole alignment is achieved. CAUTION: ^ Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock speed sensor ring teeth while handling or during assembly. ^ The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case. 2. Press the ring gear and anti-lock speed sensor ring on the differential case using the ring gear as a pilot. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 433 3. Coat the threads of the ring gear retaining bolts with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1. Install the bolts and alternately and evenly tighten to 95-115 Nm (70-85 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 434 Axle Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. From inside engine compartment, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor retaining bolt from front spindle and slide sensor out of mounting hole. INSTALLATION For installation, follow removal procedures in reverse order. Tighten retaining bolt to 4.5-6.8 Nm (40-60 in lb). Rear REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratico■ system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143 mm (0.005-0.045 inches). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft. lbs.). 5. Push the connector on the speed sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 441 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 442 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 443 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 444 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 445 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 453 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Page 458 Clutch Switch: Service and Repair 1. Disconnect wiring harness from clutch pedal position switch. 2. Pull orientation clip away from clutch pedal position switch to separate it from pin on switch, then rotate switch to expose white plastic cover. 3. Push tabs together, allowing cover to slide rearward and separate from switch, then remove switch from push rod. 4. Reverse procedure to install. Do not overtighten screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair 1. Disconnect ground cable at rechargeable telephone power pack battery, then remove steering wheel horn pad attaching screws. 2. Lift horn pad from steering wheel and remove connector from steering wheel horn pad. 3. Remove and discard steering wheel attaching bolt, then remove steering wheel from upper shaft using steering wheel puller tool No. T67L-3600-A, or equivalent. 4. Remove steering column lower trim shroud, then the straps securing brush assembly wire at ignition switch and column tube. 5. Remove screw attaching speed control brush to upper bearing retainer plate, then the speed control brush assembly wire and connector assembly through opening in upper bearing retainer plate. 6. Clean all old grease from slip rings and speed control brush, then apply new coat of Speed Control Slip Ring Grease part No. E8AZ-19590-A, or equivalent. 7. Reverse procedure to install, noting the following: a. Route brush wire so it does not interfere with trim shroud installation and is not pierced by retaining screws. b. Align index mark on steering wheel with index mark on shaft. c. Install new steering wheel bolt. Torque steering wheel bolt to 23-33 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations Oil Pressure Switch: Component Locations All Except Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 467 Limited Edition And Electronic Group Left Hand Side Of Engine, Next To Power Steering Pump Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 468 Oil Pressure Switch: Connector Locations Left Hand Side Of Engine, Next To Power Steering Pump Oil Pressure Sending Unit Connector # C175 .............................................................................................................................................................. ....... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations Ambient Temperature Sensor: Locations Limited Edition And Electronic Group The Ambient Temperature Sensor is located at the left front of engine compartment, in front of radiator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations > Page 473 Ambient Temperature Sensor: Description and Operation PURPOSE The Ambient Temperature Sensor is used by the air conditioning system to determine the outside air temperature. OPERATION The Ambient Temperature Sensor sends a signal to overhead console to indicate outside air temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning > Page 478 Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 479 Blower Motor Switch: Description and Operation PURPOSE The Blower Switch allows the driver to select LO, MED LO, MED HI or HI blower motor speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 480 Blower Motor Switch: Testing and Inspection Component Testing Procedure Schematic Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C High Pressure Cutout Switch <--> [High Pressure Sensor / Switch, HVAC] > Component Information > Description and Operation A/C High Pressure Cutout Switch: Description and Operation PURPOSE To protect A/C system from damage by interupting power to the compressor during times of high system pressure. OPERATION The A/C high pressure cutout switch opens at 460-490 psi shutting OFF the A/C compressor. This switch is closed at 230-290 psi and allows compressor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation PURPOSE To supply an electrical signal to operate the fuel gauge. OPERATION The Sender is a variable resistor connected to a float in the fuel tank, which determines the amount of fuel in tank. When fuel is low, resistance is low (22.5 ohms); when fuel is high, resistance is high (145 ohms). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Testing and Inspection Backup Lamp Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation PURPOSE The Brake On/Off (BOO) signal is received by the Powertrain Control Module (PCM) when the brakes are APPLIED. The PCM uses this signal to modify the operation of the Torque Converter Clutch (TCC) (if equipped), A/C compressor (if equipped), and idle speed during periods of decel and idle with the brakes APPLIED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 499 Brake Light Switch: Service and Repair REMOVAL Fig. 9 Stop Light Switch Replacement 1. Disconnect electrical connector from switch, Fig. 9. 2. Remove hairpin clip, then slide switch, pushrod, nylon washer and bushings away from pedal. 3. Remove washer, then the switch by sliding switch up or down. INSTALLATION 1. Position switch so that U-shaped side is nearest pedal and directly over or under pin. 2. Slide switch up or down, trapping vacuum booster input rod and bushing between switch side plates. 3. Push switch and pushrod assembly toward brake pedal arm, then assemble plastic washer to pin and install hairpin clip to retain assembly. 4. Connect electrical connector to switch, then check for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 503 Fog/Driving Lamp Switch: Description and Operation PUPOSE The Fog Lamp Switch directs power to energize the fog lamp relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 507 Hazard Warning Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 508 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation PURPOSE The Headlamp Dimmer Switch allows vehicle operator to select high/low beam headlamp operation or the flash-to-pass feature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 512 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 513 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only Headlamp Switch: Testing and Inspection All Except Limited Edition and Electronic Group Only Component Testing Procedure Terminal Location On Switch Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only > Page 518 Headlamp Switch: Testing and Inspection Limited Edition and Electronic Group Only Component Testing Procedure Headlamp Switch (Limited/Electronic) Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 519 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable, remove ash tray assembly and two finish panel retaining screws, then the finish panel (snaps off). 2. Remove rear window wash/wipe and heated rear light switch assembly (snaps out). Fig. 11 Headlamp Switch Replacement. 3. Pull headlamp switch knob to ON position, then depress shaft release button on switch and remove knob and shaft assembly. 4. Remove bezel nut, pull switch down through opening, disconnect electrical connector, then remove switch. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 523 Turn Signal Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 524 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 529 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 540 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 541 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 547 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 548 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 553 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 559 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 562 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 563 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 564 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 565 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 566 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 572 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 573 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 574 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 575 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 576 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 577 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions Clutch Pedal Position Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 582 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 584 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 585 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 586 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 587 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 588 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 589 Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 590 Neutral Drive Input Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Page 591 Clutch Pedal Position Switch: Description and Operation PURPOSE The Clutch Pedal Position (CPP) switch provides an input to the Powertrain Control Module (PCM), allowing it to compensate for changes in engine load resulting from clutch operation. The PCM adjusts the idle speed and air/fuel ratio according to input from the CPP switch. OPERATION A 5.0 volt reference signal is applied to the CPP from the PCM. The CPP switch is open with the clutch pedal up and closed when down. When the switch is closed it applies ground, through the signal return circuit, to the CPP circuit, informing the PCM that the clutch pedal is depressed. RELATED DIAGNOSTIC TROUBLE CODES DTC 528 - CPP circuit failure, during Key On Engine OFF (KOEO) self-test or while cranking the PCM sensed a high voltage (clutch pedal not depressed) on the CPP circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 596 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 597 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 598 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 599 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 600 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 605 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 606 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 609 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 610 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 611 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 612 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 613 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 614 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 615 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 617 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 618 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 619 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations Cylinder Identification Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Cylinder Identification Sensor (CID), or Camshaft Position Sensor (CMP) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations > Page 623 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal Cylinder Identification Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 626 Cylinder Identification Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 627 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 628 Cylinder Identification Sensor: Testing and Inspection Refer to Computers and Controls: System Diagnosis: Flow of Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 629 Cylinder Identification Sensor: Service and Repair For California, Sequential Fuel Injected (SFI) Models Only REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 630 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 631 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 632 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications Intake Air Temperature Sensor: Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values Notes: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Ambient temperature should be above 10°C (50°F) to receive acceptable input from the Intake Air Temperature (IAT) sensor. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications > Page 637 Intake Air Temperature Sensor: Mechanical Specifications TORQUE SPECIFICATION Intake air temperature sensor ......................................................................................................................................................... 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 638 Intake Air Temperature Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 639 Intake Air Temperature Sensor: Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 640 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the incoming air flow. The Powertrain Control Module (PCM) uses this information to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The IAT is a two lead thermistor type sensor with a negative temperature coefficient and is located in the intake air flow path. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the IAT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the incoming air increases the resistance of the IAT decreases and the voltage drop across the IAT decreases. A decrease in air temperature will increase the resistance of the IAT and raise the voltage drop across the sensor. The normal operating range of the IAT is 3.50 volts (50°F) to 1.02 volts (158°F). Note: Due to its negative temperature coefficient minor increases in resistance across the IAT circuit harness and ground connections can result in temperature values that are much lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 64/112 - The IAT sensor output is less than the self-test minimum, 0.2 volts. DTC 54/113 - The IAT sensor output is greater than the self-test maximum, 4.6 volts. DTC 24/114 - The IAT sensor output is out of self-test range, 0.3-3.7 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 641 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect electrical connector from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from intake manifold. INSTALLATION 1. To install, reverse removal procedure. 2. Tighten IAT sensor to 8-13 Nm (6-8 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. 3. Connect negative battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Heated Oxygen (HO2S) Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 646 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 647 Heated Oxygen (HO2S) Sensor: Technical Service Bulletins Heated Exhaust Gas Oxygen Sensor Application Chart Article No. 94-16-9 08/10/94 EXHAUST - HEATED OXYGEN SENSOR (H02S) - APPLICATION CHART FORD: 1991-94 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1991-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1993-94 MARK VIII LIGHT TRUCK: 1991-94 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER MEDIUM/HEAVY TRUCK: 1991 F & B SERIES ISSUE: Quick Reference Heated Oxygen Sensor (H02S) Application Charts have been developed to assist technicians and parts managers in correct parts usage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 648 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 649 ACTION: Refer to the appropriate Quick Reference Heated Oxygen Sensor (HO2S) Application Chart for Passenger Car or Truck, Figures 1 and 2, to make sure that the correct service sensor is installed. In some cases, new applications are shown. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 650 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications Heated Oxygen (HO2S) Sensor: Electrical Specifications HEATER ELEMENT RESISTANCE Hot to warm ......................................................................................................................................... .................................................. 5.0-30.0 ohms Room temperature .................................................... ............................................................................................................................... 2.0-5.0 ohms HO2S SWITCHING HO2S signal ........................................................................................................................................ .......................... 0.3-0.9 volts within 3 seconds After driving 55 mph for 5 minutes. Testing procedures may be found under System Testing / Pinpoint tests. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications > Page 653 Heated Oxygen (HO2S) Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Heated oxygen sensor .............................................................................................................................................................. 36-46 Nm (26-34 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #1 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 656 Heated Oxygen Sensors The Heated Oxygen Sensor #1 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 657 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #2 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 658 Heated Oxygen Sensors The Heated Oxygen Sensor #2 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 659 HO2S Diagram Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 660 Heated Oxygen (HO2S) Sensor: Description and Operation Heated Oxygen Sensor PURPOSE The Heated Exhaust Gas Oxygen Sensor(HO2S) detects the presence of oxygen in the exhaust system and produces a variable voltage according to the amount of oxygen present. When operating in closed loop the Powertrain Control Module (PCM) monitors this input and correspondingly changes the duration of the fuel injection pulse width to achieve an air/fuel ratio of 14.7:1. CONSTRUCTION The sensor is a zirconium dioxide ceramic thimble with a platinum surface electrode. The sensor is threaded into the exhaust manifold with a sampling tip extending into the exhaust stream. Heated Oxygen Sensor Operation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 661 OPERATION The zirconium dioxide in the sensor is electrically sensitive to differences in the amount of oxygen present between two sources. The outside of the sensor is vented to the atmosphere while the inside is exposed to the exhaust stream. The differing amounts of oxygen present between the two sources causes the sensor to generate a voltage. A rich fuel mixture will result in a low level of oxygen present in the exhaust. This will produce a larger difference in oxygen levels sensed by the HO2S which will result in a higher voltage being produced. A lean fuel mixture will result in a high level of oxygen present in the exhaust. This will produce a smaller difference in oxygen levels sensed by the HO2S which will result in a lower voltage being produced. Normal operating range for the HO2S is 0.0 volts (lean condition) to 1.1 volts (rich condition). The HO2S temperature must be above 600°F to operate properly. To minimize heat up time, a heating element is incorporated into the sensor. Heated Oxygen Sensor The HO2S uses a 4 wire connection. - HO2S wire is the sensor output. - SIG RTN is the sensor ground. - 12.0 volt power supply for the sensor heater, from the Ignition Run circuit. - Ground wire for the sensor heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 662 Heated Oxygen (HO2S) Sensor: Service and Repair Heated Oxygen Sensors REMOVAL NOTE: If excessive force is needed to remove Heated Oxygen Sensor (HO2S), lubricate HO2Ss with penetrating lubricant E8AZ-19A501-B or equivalent prior to removal. 1. Disconnect negative battery cable. 2. Disconnect HO2Ss from engine control sensor extension wiring (12A690). 3. Raise vehicle on hoist. 4. Remove HO2Ss. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten HO2Ss to 36-46 Nm (26-34 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 667 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 668 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 673 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 674 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 675 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 676 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 677 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 678 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 679 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 682 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 683 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 684 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 685 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 686 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 690 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 691 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Sensor resistance ................................................................................................................................ ............................................................. 190-250 ohms Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 695 Vehicle Speed Sensor: Locations Component Locations The Vehicle Speed Sensor is attached to transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 696 Vehicle Speed Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 697 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) PURPOSE The Vehicle Speed Sensor (VSS) signal is used by the Powertrain Control Module (PCM) to determine vehicle speed. OPERATION The VSS produces AC signals proportional to vehicle speed. This signal is sent to the PCM and is converted into a vehicle speed value, stored in RAM memory. The PCM utilizes this value to aid in controlling torque converter lock-up, coolant fan control, vehicle speed control, air/fuel ratio and ignition timing. Vehicle Speed Sensor Schematic CONSTRUCTION The VSS is a variable reluctance sensor that generates a sine wave type waveform with a frequency that is proportional to the speed of the vehicle. RELATED DIAGNOSTIC TROUBLE CODES DTC 29/452 - PCM detected an error in the VSS output (continuous memory code). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 703 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 704 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 714 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 715 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 721 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 722 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96225 > Oct > 96 > Mass Air Flow Sensor Assembly Replacement > Page 727 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise Idler Pulley: All Technical Service Bulletins Accessory Drive Belt - Squeal or Hoot Noise Article No. 96-14-9 07/01/96 ^ FRONT END ACCESSORY DRIVE (FEAD) "SQUEAL/HOOT" - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) ^ NOISE - "SQUEAL/HOOT" FROM FRONT END ACCESSORY DRIVE (FEAD) AREA - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) FORD: 1991-96 THUNDERBIRD 1994-96 MUSTANG LIGHT TRUCK: 1991-94 EXPLORER 1991-95 AEROSTAR 1997 F-150 ISSUE: Some vehicles may experience a "squeal/hoot" noise during cold start-up (usually after cold soak at temperatures of -18°C/0°F (or below) coming from the Front End Accessory Drive (FEAD) area. This may be caused by the tolerance of the grease being used within the idler pulley bearing in cold temperatures. ACTION: Confirm the noise is coming from the idler pulley (or the tensioner pulley bearing for the 4.0L Explorer) and replace the idler pulley which has a revised composition grease to reduce the possibility of noise in cold temperatures. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using a technician's stethoscope, check for noise at the idler pulley (4.0L Explorer, at the tensioner pulley bearing). WARNING: DO NOT RUN THE ENGINE FOR MORE THAN 30 SECONDS WITH THE FEAD BELT REMOVED. 2. Remove the FEAD belt and start the engine. With the engine running, check to see if the noise is still present. If the noise is not present, proceed to Step 3. If the noise is still present, this TSB is no longer applicable. 3. Replace the idler pulley with a revised idler pulley selected from the Application Chart. Refer to the appropriate model/year Service Manual for removal and installation procedures. NOTE: THE BOLT SECURING THE IDLER PULLEY TO THE TENSIONER ASSEMBLY IS A LH THREAD AND SHOULD BE TORQUED TO 40.7 N-m (30 LB-FT) MINIMUM. PART NUMBER PART NAME F5PZ-8678-AA Idler Pulley F6PZ-8678-AB Idler Pulley OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise > Page 733 OPERATION DESCRIPTION TIME 961409A Replace Idler Pulley Or 0.3 Hr. Tensioner Pulley DEALER CODING CONDITION BASIC PART NO. CODE 8678 56 OASIS CODES: 497000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise > Page 739 OPERATION DESCRIPTION TIME 961409A Replace Idler Pulley Or 0.3 Hr. Tensioner Pulley DEALER CODING CONDITION BASIC PART NO. CODE 8678 56 OASIS CODES: 497000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 742 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 743 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 744 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 745 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 746 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations INERTIA FUEL SHUTOFF SWITCH LOCATION Inertia Fuel Shutoff Switch Location Located on the toe-board to the right of the transmission hump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 750 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "OFF" in the event of a collision. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump looses power. The inertia switch must then be manually reset before the engine can be restarted. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 751 Fuel Pump Inertia Switch: Service and Repair WARNING: Do not reset the inertia switch button if you see or smell fuel. 1. Turn ignition switch to OFF. 2. Check for leaking fuel in the engine compartment, fuel lines and fuel tank. 3. If no fuel is apparent, reset the Inertia Fuel Shutoff (IFS) switch by pushing the reset button on top of switch. 4. Turn ignition switch to START for a few seconds, then to OFF. 5. Again, check for leaking fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 756 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 757 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 758 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 759 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 760 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 761 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 762 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 765 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 766 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 767 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 768 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 769 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 776 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 777 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 778 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 779 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 780 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 781 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 786 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 787 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 798 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 799 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 800 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The Profile Ignition Pickup (PIP) sensor is a Hall-effect type switch located in the distributor. It sends the Powertrain Control Module (PCM) information on engine speed and crankshaft position. The Hall device operates by the manipulation of magnetic fields. When a rotor vane ENTERS the space between the two halves of the stator pick-up, the magnetic field is altered, turning ON the signal to the PCM. When the vane LEAVES the stator gap, the magnetic field returns to normal, and the signal to the PCM is turned OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 812 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 813 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 819 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 820 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 821 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 822 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 827 Clutch Pedal Position Switch: Description and Operation OPERATION The Powertrain Control Module (PCM) sends out a 5 volt reference to the Clutch Pedal Position (CPP) switch. When the switch is "OPEN" (clutch DEPRESSED), the PCM senses voltage. When the switch is "CLOSED" (clutch RELEASED), the PCM senses no voltage. The PCM uses this input to determine engine load and to adjust idle speed accordingly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 828 Clutch Pedal Position Switch: Service and Repair Fig. 8 Clutch Interlock 3-way Switch REMOVAL 1. Disconnect electrical connector from switch located on clutch master cylinder push rod, Fig. 8. 2. Pull orientation clip away from switch to separate pin, then rotate switch to expose plastic retainer. 3. Push tabs together to allow retainer to slide rearward and separate from switch. 4. Remove switch from push rod. INSTALLATION 1. Install switch onto master cylinder push rod, ensuring that switch is properly seated. 2. Install plastic retainer, then rotate switch into position and attach orientation clip. 3. Connect electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 837 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 838 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 844 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 845 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 846 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 847 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Park/Neutral Position Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 851 Neutral Safety Switch: Description and Operation PURPOSE The Park/Neutral Position Switch allows driver to start vehicle in PARK or NEUTRAL position of the automatic transmission only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 852 Neutral Safety Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 853 Neutral Safety Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable, then raise and support vehicle. Fig. 6 Neutral Start Switch 2. Disconnect electrical connector from switch, Fig. 6 then remove switch and O-ring using neutral start switch socket T74P-77247-A or equivalent. NOTE: The Neutral start switch socket is a thin wall socket, other types of sockets could puncture walls of switch. INSTALLATION 1. Install neutral start switch using socket and torque to 7-10 ft lb. 2. Connect electrical connector to switch, then lower vehicle. 3. Connect battery ground cable, then check operation of switch with parking brake engaged. Engine should start with selector lever in N or P only, and back-up lamps should illuminate with selector lever in R only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 859 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 860 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views Power Window Switch: Locations Behind Instrument Panel Views All Except Limited Edition And Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 876 Component Locations Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 877 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 878 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 879 Power Window Switch: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 880 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 881 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 882 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 883 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 886 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 887 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 888 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 889 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 891 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 892 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 893 Power Window Switch: Connector Views Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 895 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 896 Power Window Switch: Electrical Diagrams Power Windows (2 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Power Windows (4 Door) Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 899 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch > Page 906 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 907 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch > Page 912 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test Wiper Switch: Testing and Inspection Continuity Test Fig. 6 Wiper Switch Continuity Test. Except 88 Bronco II & Ranger 1. Check continuity between switch terminals. 2. To detect marginal operation of switch, move switch lever while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test > Page 915 Wiper Switch: Testing and Inspection Wiper, Washer Interval Test Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch Wiper Switch: Service and Repair Multifunction Switch REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch > Page 918 Wiper Switch: Service and Repair Rear Wiper Switch 1. Disconnect battery ground cable, then remove ashtray and instrument cluster trim panel. 2. Remove switch mounting bezel containing switches, then disconnect switch electrical connector and remove switch. 3. Reverse procedure to install, checking wiper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 928 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 929 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 930 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 931 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 932 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 933 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 934 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 935 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 941 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 942 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 943 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 944 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 945 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 946 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 947 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 948 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings Alignment: All Technical Service Bulletins Suspension/Steering - Front Alignment Settings Article No. 93-23-24 11/10/93 ^ SUSPENSION - FRONT - ALIGNMENT SETTINGS ^ SUSPENSION - FRONT ALIGNMENT - SERVICE PROCEDURES - 1994 MODEL SERVICE PARTS USAGE LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER ISSUE: Front end alignment on light trucks may occasionally require adjustment. Information about the service parts available to provide the adjustments and service setting objective is featured in this article. ACTION: If light truck Service Manual diagnostics indicate the need for front alignment adjustment, use the optimum alignment settings and caster/camber adjustment parts list provided in this TSB Article. Refer to the appropriate light truck Service Manual, Section 04-00 for service details. DETAILED SERVICE PROCEDURE The chart has been created to give optimum alignment settings and to recommend allowable ranges for all light truck alignments. The ranges recommended in this chart are only recommended guidelines within which most customers would not indicate concern with vehicle alignment. When Service Manual diagnostics indicate that an alignment adjustment may be required to resolve a customer concern, all of the vehicle's alignment parameters should be set to their optimum values to assure customer satisfaction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 953 REQUIRED CONDITIONS BEFORE CHECKING ALIGNMENT: ^ No driver and/or passenger ^ Full fluids ^ All tires set to specified air pressure ^ All tire sizes comparable to original equipment ^ Vehicle configured to normal operated condition (not to exceed max. front GAWR, max. rear GAWR and/or max. GVW. DEFINITIONS 1. Camber Average is defined as LH camber plus RH camber divided by 2 (LH CAMBER + RH CAMBER) / 2. Vehicles set to this specification, as measured with the vehicle loaded to normal loading conditions will result in optimum tire wear. 2. Caster Average is defined as LH caster plus RH Caster divided by 2 (LH CASTER + RH CASTER) / 2. These are NOT recommended values for settings. They are only maximum and minimum limitations. Vehicles outside these limits may exhibit the following: ^ Vehicles which exceed the maximum caster value may result in shimmy concerns. ^ Vehicles operated below the minimum caster value may result in wander and poor steering returnability concerns. 3. Camber Split is defined as LH camber minus RH camber (LH CAMBER - RH CAMBER) 4. Caster Split is defined as LH caster minus RH Caster (LH CASTER - RH CASTER) SPECIAL NOTE - CASTER/CAMBER OUT OF RANGE Vehicles with average caster and/or camber significantly out of specified ranges may have a ride height out of normal operating range. Normal service procedures may not provide adequate adjustment to bring the alignment to the preferred specification. If ride height appears to be an issue, investigate as follows: ^ Front ride height can be below specification if the front loading exceeds the rated capacity listed on the certification label. Weigh the front end and compare to the certification label to determine if an overload condition exists. If overloaded, adjust weight to bring vehicle back into compliance with the published weight limits, or rerate the front suspension within the guidelines of the 1994 Body Builders Layout Book. ^ Front ride height can be abnormally high on lightly loaded vehicles equipped with heavy duty front suspension options or maximum FGAWR options. Compare the ride height of the frame-to-ground guidelines at the wheel centers published in the 1994 Body Builder's Layout Book, and adjust loading as required or revise front suspension rating within the guidelines in the 1994 Body Builder's Layout Book. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 954 The alignment service parts usage chart provides correct parts usage for each type of vehicle. Select the appropriate parts group from these charts and use the caster/camber parts information chart (refer to Figure 1) to order the parts required. For labor times, refer to the 1994 Service Labor Time Standards Manual Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 955 Parts Block OTHER APPLICABLE ARTICLES: 92-25-11, 92-8-13 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings Alignment: All Technical Service Bulletins Suspension/Steering - Front Alignment Settings Article No. 93-23-24 11/10/93 ^ SUSPENSION - FRONT - ALIGNMENT SETTINGS ^ SUSPENSION - FRONT ALIGNMENT - SERVICE PROCEDURES - 1994 MODEL SERVICE PARTS USAGE LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER ISSUE: Front end alignment on light trucks may occasionally require adjustment. Information about the service parts available to provide the adjustments and service setting objective is featured in this article. ACTION: If light truck Service Manual diagnostics indicate the need for front alignment adjustment, use the optimum alignment settings and caster/camber adjustment parts list provided in this TSB Article. Refer to the appropriate light truck Service Manual, Section 04-00 for service details. DETAILED SERVICE PROCEDURE The chart has been created to give optimum alignment settings and to recommend allowable ranges for all light truck alignments. The ranges recommended in this chart are only recommended guidelines within which most customers would not indicate concern with vehicle alignment. When Service Manual diagnostics indicate that an alignment adjustment may be required to resolve a customer concern, all of the vehicle's alignment parameters should be set to their optimum values to assure customer satisfaction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 961 REQUIRED CONDITIONS BEFORE CHECKING ALIGNMENT: ^ No driver and/or passenger ^ Full fluids ^ All tires set to specified air pressure ^ All tire sizes comparable to original equipment ^ Vehicle configured to normal operated condition (not to exceed max. front GAWR, max. rear GAWR and/or max. GVW. DEFINITIONS 1. Camber Average is defined as LH camber plus RH camber divided by 2 (LH CAMBER + RH CAMBER) / 2. Vehicles set to this specification, as measured with the vehicle loaded to normal loading conditions will result in optimum tire wear. 2. Caster Average is defined as LH caster plus RH Caster divided by 2 (LH CASTER + RH CASTER) / 2. These are NOT recommended values for settings. They are only maximum and minimum limitations. Vehicles outside these limits may exhibit the following: ^ Vehicles which exceed the maximum caster value may result in shimmy concerns. ^ Vehicles operated below the minimum caster value may result in wander and poor steering returnability concerns. 3. Camber Split is defined as LH camber minus RH camber (LH CAMBER - RH CAMBER) 4. Caster Split is defined as LH caster minus RH Caster (LH CASTER - RH CASTER) SPECIAL NOTE - CASTER/CAMBER OUT OF RANGE Vehicles with average caster and/or camber significantly out of specified ranges may have a ride height out of normal operating range. Normal service procedures may not provide adequate adjustment to bring the alignment to the preferred specification. If ride height appears to be an issue, investigate as follows: ^ Front ride height can be below specification if the front loading exceeds the rated capacity listed on the certification label. Weigh the front end and compare to the certification label to determine if an overload condition exists. If overloaded, adjust weight to bring vehicle back into compliance with the published weight limits, or rerate the front suspension within the guidelines of the 1994 Body Builders Layout Book. ^ Front ride height can be abnormally high on lightly loaded vehicles equipped with heavy duty front suspension options or maximum FGAWR options. Compare the ride height of the frame-to-ground guidelines at the wheel centers published in the 1994 Body Builder's Layout Book, and adjust loading as required or revise front suspension rating within the guidelines in the 1994 Body Builder's Layout Book. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 962 The alignment service parts usage chart provides correct parts usage for each type of vehicle. Select the appropriate parts group from these charts and use the caster/camber parts information chart (refer to Figure 1) to order the parts required. For labor times, refer to the 1994 Service Labor Time Standards Manual Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 963 Parts Block OTHER APPLICABLE ARTICLES: 92-25-11, 92-8-13 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 964 Alignment: By Symptom Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 965 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 966 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 967 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 968 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 969 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 970 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 971 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 972 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 973 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 974 b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 975 g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 976 ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 977 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 978 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 979 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 980 ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 981 Alignment: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Alignment: Service and Repair Camber 1. Measure caster and camber, noting difference between specification and actual measurement. Fig. 1 Caster/Camber Variation Chart 2. Select correct service adjuster, Fig. 1. Select adjuster that will bring alignment to specifications with the smallest side to side variation. 3. Remove front wheel and tire assembly. 4. Remove upper ball joint pinch bolt, then using removal tool No. T64P-3590-F or tool No. D81T-3010-B or equivalent, remove adjuster. 5. Install new adjuster, then using suitable 11/2 inch socket rotate adjuster to specified position. 6. Install ball joint pinch bolt torquing to 48-65 ft lb, install snap ring. 7. Install front wheel and tire assembly, then recheck alignment. NOTES: ^ Caster and camber adjustment is possible with adjusters available in 1/2°, 1° and 11/2° increments. ^ One adjuster is used to adjust both caster and camber. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 984 Alignment: Service and Repair Caster 1. Measure caster and camber, noting difference between specification and actual measurement. Fig. 1 Caster/Camber Variation Chart 2. Select correct service adjuster, Fig. 1. Select adjuster that will bring alignment to specifications with the smallest side to side variation. 3. Remove front wheel and tire assembly. 4. Remove upper ball joint pinch bolt, then using removal tool No. T64P-3590-F or tool No. D81T-3010-B or equivalent, remove adjuster. 5. Install new adjuster, then using suitable 11/2 inch socket rotate adjuster to specified position. 6. Install ball joint pinch bolt torquing to 48-65 ft lb, install snap ring. 7. Install front wheel and tire assembly, then recheck alignment. NOTES: ^ Caster and camber adjustment is possible with adjusters available in 1/2°, 1° and 11/2° increments. ^ One adjuster is used to adjust both caster and camber. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 985 Alignment: Service and Repair Preliminary Inspection Inspect the following components, adjust, repair or replace as required prior to performing front wheel alignment. 1. Inflate tires to cold specifications. 2. Ensure front tires are of same size, ply rating and load rating. 3. Inspect for excessive wheel bearing endplay. 4. Inspect for worn or damaged spindle ball joints. 5. Inspect steering gear mounting bolts for proper torque. 6. Inspect radius arm or bent or damaged condition. 7. Inspect radius arm to frame bushings for looseness or wear. 8. Inspect suspension components for wear or damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 986 Alignment: Service and Repair Toe 1. Loosen clamp bolts at each end of spindle connecting rod tube, then rotate the sleeve until correct toe alignment of 1/32 inch is obtained. Fig. 4 Toe-In Adjustment 2. Center clamps between adjustment sleeve nibs, then position bolts horizontally with clamps nuts positioned as shown in Fig. 2. 3. Recheck toe-in adjustment, then check that steering wheel spokes are properly positioned and adjust as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 987 Alignment: Service and Repair Vehicle Lean Correction Front Lean NOTE: Codes identifying the front and rear spring options and springs are printed on the Safety Standard Certification Label. If a spring requires replacement because of damage or sagging, replace only with the same part as specified on the label. In rare instances, the spring codes will not reflect the springs as installed due to a DSO option or Assembly Plant substitution. if a DSO option number is shown on the certification label, the district office can establish whether springs are affected. If the factory-installed springs do not agree with the code printed on the Safety Standard Certification Label (right and left spring part number should match), it is advisable to replace springs in pairs. 1. Measure the left and right front ride heights by measuring the height of the right and left front fender lip openings. Add 8 mm (5/16 inch) to the right side ride height measurement. 2. Compute the difference between left and right ride heights as figured in Step 1 above. a. If the difference exceeds 3-9 mm (1/8-3/8 inch) and is less than 19 mm (3/4 inch) measured at the wheelhouse opening to ground, add 1 shim to the side of the vehicle that is low. b. The shim is to be placed under the lower spring seat; service shim (part number 389117-S2) can be used without a front stabilizer bar. c. If there is a computed side-to-side difference of 19 mm (3/4 inch) or more in the left/right wheelhouse openings, swap front coil springs from side-to-side. If the lean condition follows the spring (lean now on other side of the vehicle), replace both springs with new ones. d. Changing front ride height by adding the service shim also affects caster angles. Adding the 4.5 mm thick shim (part number 389117-S2 or equivalent) may reduce caster by up to 0.40 degrees on the side to which the shim is added. Rear Lean With the underslung rear suspension, use of shims will not have any effect on a lean condition. Use the following procedure to verify and correct a rear lean condition. 1. Measure rear ride height by measuring the height of the right and left rear fender lip openings. 2. Compute the difference. 3. Inspect the vehicle for any excess loads which might weigh the vehicle down on one side more than the other. Usually a weight of at least 50 pounds is required to cause such a lean. 4. If lean condition is not caused by weight, swap the rear springs from side-to-side. 5. If the lean changes sides, the lean condition is most likely caused by a bad spring. Replace both springs. 6. If the lean condition did not change when the springs were changed, factors other than suspension are the cause. Side-to-Side Lean Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 988 1. Side-to-side vehicle lean should be verified by measuring the fender lip-to-ground dimensions A and B. Normal acceptable limits are: a. Maximum of 16 mm (5/8 inch) variance between left and right front wheel lips to ground. b. Maximum of 19 mm (3/4 inch) variance between left and right rear wheel lips to ground. 2. Once a lean condition has been verified, perform the following steps. a. Place the vehicle on a flat, smooth surface. Vehicles must be sitting on the wheels and tires, not on a hoist, jack or jack stands. b. Inspect vehicle for any heavy add-ons that may cause excessive weight on any corner of the vehicle. Vehicle should be empty, fuel tanks full, no cargo in the pick-up box or rear body section. c. Check all wheels and tires: - Wheel size and design, tire size and tread should be indicated on the Vehicle Safety Standard Certification Label. - Wheels must be same size and design, right and left side, on each axle. - Tires must be same brand, tire size, tread design and equal tread wear side-to-side on each axle. - Check air pressure of all tires; inflate to specifications indicated on the Vehicle Safety Standard Certification Label. d. Check front and rear suspension. Verify the same spring is on left/right front and left/right rear. - Front coil springs have I.D. tags indicating the part number. - Rear springs have the part number stamped on the bottom left just behind the U-bolt attachment. - If I.D. tags are missing from the front springs, there is no sure way of identifying which springs are installed on the vehicle. It is advisable to order springs in pairs only. e. Bounce the vehicle's front and rear suspension to normalize the vehicle static ride height. f. Measure the height of the right and left fender lip openings again. If the differences are still greater than 16 mm (5/8 inch) between left or right front and/or 19 mm (3/4 inch) between left and right rear, factors other than suspension are the cause. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 994 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 998 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 999 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Air/fuel mixture requirement is computer controlled and not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments NOTE: Curb and fast idle speeds are controlled by the Powertrain Control Module (PCM) and Idle Air Control (IAC) valve assembly. The IAC valve and idle speed is not adjustable. A large increase or decrease in closed plate airflow from the calibrated level will not allow effective idle speed control. Throttle Body Assembly Throttle bodies with sludge tolerant design are identified with a yellow/black decal. The throttle body must not be cleaned inside the bore, as this cleaning will impair the sensitive coating. Sludge accumulation will not affect the idle air flow. The cleaning procedure for the IAC valve still applies. RPM LIMIT CHECK PROCEDURE - Self-Test constant tone STAR tester or equivalent scanner required 1. Activate engine running Self-Test. 2. After diagnostic trouble code 11 or 111 has been displayed, unlatch and within 4 seconds latch the Self-Test Input (STI) button. 3. A single pulse code indicates the entry mode, then observe the Self-Test Output (STO) of the STAR tester. - A constant tone, solid light or "STO LO" readout indicates base idle rpm is within range. - Beeping tone, flashing light, or STO LO readout at 8.0 Hz indicates Throttle Position (TP) is out of range due to over adjustment. - Beeping tone, flashing light, or STO LO readout at 4.0 Hz indicates base idle rpm is too fast. - Beeping tone, flashing light, or STO LO readout at 1.0 Hz indicates base idle is too slow. 4. To exit test, unlatch STI button, then wait 4 seconds for reinitialization (after 10 minutes it will exit by itself). 5. If the idle rpm (engine warm, in Neutral, A/C "Off") is not within limits, refer to Testing and Inspection / Procedures / Air Induction Diagnosis for other possible causes of idle problem. See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection/Pinpoint Tests/AIS - Air Induction Diagnosis Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Engine - Water Entry Through Air Intake System Air Cleaner Fresh Air Duct/Hose: Technical Service Bulletins Engine - Water Entry Through Air Intake System Article No. 94-3-8 02/09/94 ^ AIR INTAKE - 2.9L, 3.0L, 4.0L EFI ENGINES - WATER ENTRY THROUGH AIR INTAKE SYSTEM ^ ENGINE - 2.9L, 3.0L, 4.0L EFI - POSSIBLE INTERNAL DAMAGE FROM WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK: 1986-90 BRONCO II 1986-94 RANGER 1991-94 EXPLORER This article is being republished in its entirety to add 1993-94 4.0L Ranger, 1993-94 3.0L Ranger and 1993-94 4.0L Explorer vehicles. ISSUE: Reports have been received of internal engine damage caused by water entering the engine through the air intake system. This condition may occur when the vehicle is driven in normal wet conditions, such as water splash/spray from other vehicles, or when driven through shallow water. Improvements were made to the EFI engine air intake systems that have greatly reduced the number of reported incidences. ACTION: Dealers should be assured that warranty repairs will be covered unless there Is evidence of owner misuse. This warranty repair policy will remain effective unless you are notified that a waterproof air intake system has been released. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-21-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 1011 Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL NOTE: The heat supply plenum door actuating motor and hose are not serviceable items. Repair requires the replacement of the engine air cleaner intake tube and duct. 1. Remove engine air cleaner. 2. Remove heat supply hose from exhaust manifold engine air cleaner duct shroud and tube and engine air cleaner intake tube and duct. 3. Remove one retaining screw from radiator support (baffle). 4. Remove actuator motor vacuum supply hose from bi-metal sensor in engine air cleaner assembly upper cover. 5. Remove engine air cleaner intake tube and duct from vehicle. INSTALLATION 1. Position engine air cleaner intake tube and duct and install retaining screw. 2. Reassemble engine air cleaner as described in this section. 3. Connect engine air cleaner intake tube and duct to engine air cleaner. Make sure engine air cleaner intake tube and duct snaps into place. 4. Connect vacuum hose to bi-metal sensor. 5. Install heat supply hose assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation Air Cleaner Element: Description and Operation PURPOSE Filters out unwanted dust, dirt and debris. CONSTRUCTION Chemically-treated, pleated paper element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1015 Air Cleaner Element: Service and Repair Air Intake System REMOVAL 1. Loosen outlet tube clamps from air cleaner cover and throttle body. Remove the outlet tube. 2. Disconnect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 3. Disconnect the Mass Air Flow (MAF) sensor electrical connection. 4. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 5. Remove the two air cleaner cover retaining screws, then the air cleaner cover. 6. Remove the air filter element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1016 INSTALLATION 1. Install the air filter element. 2. Remove the air cleaner cover, then the two air cleaner cover retaining screws. Tighten the screws to 3 Nm (26 lb in). 3. Connect the IAT sensor electrical connector. 4. Connect the MAF sensor electrical connection. 5. Connect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 6. Install the outlet tube. Tighten the outlet tube clamps at the air cleaner cover and throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1024 Spark Plug Wire Assembly Vin X V6 Firing Order: 1 4 2 5 3 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations Ignition Timing Connector: Locations Connector Location The SPOUT connector shorting bar (C107), is located at the RF corner of the engine compartment, near EDIS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation Ignition Timing Connector: Description and Operation SPOUT / SAW Connector Operation Spout/SAW Connector DESCRIPTION The Spark Angle Word (SAW),or Spark Output (SPOUT) connector is used to open and close the circuit between the Powertrain Control Module (PCM)and the Ignition Control Module (ICM) for checking base timing. OPERATION When the SPOUT or SAW connector is inserted in the harness connector, the ICM operates according to PCM timing data (computed timing). When the SPOUT or SAW connector is removed from the harness connector, the ICM operates on the Profile Ignition Pickup (PIP) signal only (base timing). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation > Page 1031 Ignition Timing Connector: Description and Operation Octane Adjustment Switch Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1038 Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1039 Ignition Cable: Description and Operation PURPOSE Conducts high voltage from the ignition coil and deliver to each spark plug in proper sequence. CONSTRUCTION Secondary ignition wires are constructed with a carbon impregnated, multi-filament synthetic fiber core. To endure under hood temperatures, the core is surrounded by heat resistant rubber insulation. Built-in internal resistance suppresses radio static and eliminates interference. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1040 Ignition Cable: Service and Repair Spark Plug Wire Assembly REMOVAL: 1. When removing spark plug wires from the spark plugs, use the spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug insulator to free the boot. 2. Use the special tool or equivalent to pull the boot from the plug. Do not pull on the wire directly, as it may become separated from the connector inside the boot. 3. To remove the wires from the coil pack, squeeze the locking tabs of the coil wire retainer and remove using a twisting and pulling motion. Do not pull on the wire. INSTALLATION: CAUTION: Proper installation of spark plug wires is critical to vehicle operation. If one spark plug wire is not properly installed on the spark plug or ignition coil, both spark plugs connected to that coil may not fire under load. 1. Whenever a high tension wire is removed for any reason from a spark plug or ignition coil, or a new high tension wire is installed, Silicone Dielectric Compound D7AZ-19A331-A or equivalent must be applied to the boot prior to installation. Using a small tool, coat the entire interior surface of the boot. 2. Install each wire on the proper ignition coil terminal. The terminal cylinder numbers are identified on the ignition coil pack. Ensure that both coil boot retainer locking tabs have engaged. 3. Remove the wire retaining brackets from the old wiring set and install the brackets on the new wires in the same position. Install the wires and retaining brackets on the engine. 4. Connect the wires to the proper Spark plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Platinum Spark Plugs - Identification/Location Spark Plug: Technical Service Bulletins Platinum Spark Plugs - Identification/Location Article No. 94-2-8 01/26/94 ^ IGNITION SYSTEM - ELECTRONIC IGNITION (EI) PLATINUM ENHANCED SPARK PLUGS 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L ENGINES ^ ENGINE - 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L - PLATINUM ENHANCED SPARK PLUG LOCATIONS FORD: 1994 ESCORT, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Three (3) different unique styles of platinum enhanced spark plugs are produced for vehicles with Electronic Ignition (EI). Each style is distinguished by their part number suffix letters. ^ The suffix letter "P" indicates the center electrode is enhanced with platinum. ^ The suffix letter "PG" indicates the ground (side) electrode is enhanced with platinum. ^ The suffix letter "PP" indicates double platinum enhancement on both the ground (side) and center electrode. ACTION: If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter "PP" as shown on the engine decal. Refer to the following Platinum Enhanced Spark Plug Replacement Chart for correct parts usage. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000, 623000, 690000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Plug Type .......................................................... ............................................................................................................................. Motorcraft AWSF-42PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 1047 Spark Plug: Specifications Tightening Torque SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Tightening Torque ............................................. .................................................................................................................................... 7-15 ft lb (9-20 Nm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1048 Spark Plug: Description and Operation PURPOSE Spark plugs provide the path for secondary ignition system high voltage to flow to ground. OPERATION Voltage arcing between plug center and ground electrode produces the spark to ignite the air/fuel mixture. CONSTRUCTION Many spark plugs are made with an internal resistor, designed to reduce ignition system electrical interference with entertainment systems and computerized devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1049 Spark Plug: Testing and Inspection Testing For Spark 1. Remove the spark plug. 2. Connect the spark plug to the spark plug wire. 3. Hold the spark plug with insulated pliers 0.20-0.40 in (5-10 mm) from a ground. 4. Crank the engine and verify that there is a strong blue spark. If there Is no spark, replace the spark plug. Spark Plug 5. Check the following points. If a problem is found, replace the spark plug. ^ Damaged insulation ^ Worn electrodes ^ Carbon deposits. (If cleaning is necessary, use a plug cleaner or a wire brush. Clean the upper insulator also.) ^ Damaged gasket. ^ Burnt condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure ....................................................................................................................... PSI of lowest cylinder must be within 75% of highest Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Valve Arrangement (Front To Rear) ........................................................................................................................................................... L.H. I-E-I-E-I-E Valve Arrangement (Front To Rear) ........................................................................................................................................................... R.H. E-I-E-I-E-I Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 1056 Valve Clearance: Adjustments The hydraulic roller tappets have non-adjustable rocker arms. The tappets are not adjustable, and if found to be excessively worn or noisy, should be tested and replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Routing New Or Used Belt (Measured At "A") ............................................................................................................................... 480-586 Newtons (108-132 lbs) Allowable Minimum ....................................................................................................... .................................................................. 480 Newtons (108 lbs) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1060 Drive Belt Routing Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1061 Drive Belt: Adjustments No adjustments are necessary; automatic tensioner gauges when belt should be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1062 Drive Belt: Service and Repair Fig. 11 Serpentine Drive Belt Routine REMOVAL AND INSTALLATION 1. Raise tensioner by turning counterclockwise, then remove belt. 2. Install new belt over pulleys, then raise tensioner and slide belt underneath. Release tensioner to rest pulley on belt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Engine - Water Entry Through Air Intake System Air Cleaner Fresh Air Duct/Hose: Technical Service Bulletins Engine - Water Entry Through Air Intake System Article No. 94-3-8 02/09/94 ^ AIR INTAKE - 2.9L, 3.0L, 4.0L EFI ENGINES - WATER ENTRY THROUGH AIR INTAKE SYSTEM ^ ENGINE - 2.9L, 3.0L, 4.0L EFI - POSSIBLE INTERNAL DAMAGE FROM WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK: 1986-90 BRONCO II 1986-94 RANGER 1991-94 EXPLORER This article is being republished in its entirety to add 1993-94 4.0L Ranger, 1993-94 3.0L Ranger and 1993-94 4.0L Explorer vehicles. ISSUE: Reports have been received of internal engine damage caused by water entering the engine through the air intake system. This condition may occur when the vehicle is driven in normal wet conditions, such as water splash/spray from other vehicles, or when driven through shallow water. Improvements were made to the EFI engine air intake systems that have greatly reduced the number of reported incidences. ACTION: Dealers should be assured that warranty repairs will be covered unless there Is evidence of owner misuse. This warranty repair policy will remain effective unless you are notified that a waterproof air intake system has been released. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-21-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 1069 Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL NOTE: The heat supply plenum door actuating motor and hose are not serviceable items. Repair requires the replacement of the engine air cleaner intake tube and duct. 1. Remove engine air cleaner. 2. Remove heat supply hose from exhaust manifold engine air cleaner duct shroud and tube and engine air cleaner intake tube and duct. 3. Remove one retaining screw from radiator support (baffle). 4. Remove actuator motor vacuum supply hose from bi-metal sensor in engine air cleaner assembly upper cover. 5. Remove engine air cleaner intake tube and duct from vehicle. INSTALLATION 1. Position engine air cleaner intake tube and duct and install retaining screw. 2. Reassemble engine air cleaner as described in this section. 3. Connect engine air cleaner intake tube and duct to engine air cleaner. Make sure engine air cleaner intake tube and duct snaps into place. 4. Connect vacuum hose to bi-metal sensor. 5. Install heat supply hose assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation Air Cleaner Element: Description and Operation PURPOSE Filters out unwanted dust, dirt and debris. CONSTRUCTION Chemically-treated, pleated paper element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1073 Air Cleaner Element: Service and Repair Air Intake System REMOVAL 1. Loosen outlet tube clamps from air cleaner cover and throttle body. Remove the outlet tube. 2. Disconnect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 3. Disconnect the Mass Air Flow (MAF) sensor electrical connection. 4. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 5. Remove the two air cleaner cover retaining screws, then the air cleaner cover. 6. Remove the air filter element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1074 INSTALLATION 1. Install the air filter element. 2. Remove the air cleaner cover, then the two air cleaner cover retaining screws. Tighten the screws to 3 Nm (26 lb in). 3. Connect the IAT sensor electrical connector. 4. Connect the MAF sensor electrical connection. 5. Connect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 6. Install the outlet tube. Tighten the outlet tube clamps at the air cleaner cover and throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1083 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1084 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1085 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. Brake Fluid DOT 3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1097 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1098 Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1099 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1100 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLANT CAPACITY With A/C .............................................................................................................................................. .................................................................. 8.6 qts Without A/C ........................................................... ................................................................................................................................................ 7.8 qts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1103 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1108 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1109 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: A4LD 3.0 qt (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 1112 Fluid - A/T: Specifications Automatic Transmission Capacity 9.7 qt (US) Approximate. Make final check w/dipstick. Fluid Type Mercon(r) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check Fluid - A/T: Testing and Inspection Fluid Level Check CHECKING OIL LEVEL 1. With transmission in Park, engine at curb idle RPM, foot brakes applied, and vehicle on a level surface, move transmission selector lever through each range. Allow time in each range for transmission to engage, then return to Park and apply parking brake fully. NOTE: If vehicle has been operated for an extended period at high speed, in city traffic during hot weather, or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: Vehicles equipped with 4X4 applications must have the 4X4 shift selector in any position other than neutral. CAUTION: Your vehicle should not be driven if the fluid level is below the bottom hole on the dipstick and outside temperatures are above 10°C (50°F). 2. Clean all dirt from transmission dipstick cap. 3. Pull dipstick out of filler tube, wipe clean, and push dipstick back all the way into the filler tube, ensuring it is full seated. 4. Pull dipstick out of tube again and check fluid level as follows: a. With transmission at operating temperature, 150° F-170° F, fluid level should be within the cross hatched area. b. With transmission at room temperature, 70° F-95° F, fluid should be between middle and top holes. 5. If it is necessary to add fluid, use only Dexron II or equivalent. CAUTION: The use of fluid other than that specified could result in transmission malfunction and/or failure. 6. Install dipstick, ensuring it is fully seated in tube. Adding Fluid 1. The fluid type is stamped on the dipstick. Before adding any fluid, be sure that the correct type will be used. 2. Add fluid in .25L (1/2 pint) increments through the filler tube to bring the level to the correct area on the dipstick. If an overfill occurs, excess fluid should be removed. Overfill can cause the fluid to foam and spill out through the transmission vent resulting in a transmission malfunction. Undertill can result in transmission loss of engagement or slipping. This condition is most evident in cold weather or when the vehicle is parked or being driven on a hill. If the transmission fluid level is checked when the fluid is at room temperature the dipstick could indicate that fluid should be added if the dipstick is misread. If fluid is added at this time, an overfill condition could result when the fluid reaches operating temperatures of 66° C-77°C (150°F-170°F) (dipstick hot to touch). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check > Page 1115 Fluid - A/T: Testing and Inspection Transaxle Fluid Cooler Flow Test TRANSMISSION FLUID COOLER CHECK 1. Ensure linkage is properly adjusted and fluid level and control pressure are within specifications. 2. Remove transmission dipstick from filler tube and insert funnel in tube. 3. Raise and support vehicle. 4. Remove cooler return line from its fitting in the case, attach a hose to cooler return line and fasten free end of hose in funnel installed in filler tube. 5. Start engine and set idle at 1,000 RPM with transmission in Neutral. 6. Observe fluid flow at funnel. When flow is constant, it should be liberal. If there is not a liberal flow at 1,000 RPM in Neutral, low pump capacity, main circuit system leakage, stuck converter charge relief valve, or cooler system restriction is indicated. 7. To separate transmission trouble from cooler system trouble, observe flow at transmission case converter-out fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check > Page 1116 Fluid - A/T: Testing and Inspection Transmission Fluid Cooler Check TRANSMISSION FLUID COOLER CHECK 1. Ensure linkage is properly adjusted and fluid level and control pressure are within specifications. 2. Remove transmission dipstick from filler tube and insert funnel in tube. 3. Raise and support vehicle. 4. Remove cooler return line from its fitting in the case, attach a hose to cooler return line and fasten free end of hose in funnel installed in filler tube. 5. Start engine and set idle at 1,000 RPM with transmission in Neutral. 6. Observe fluid flow at funnel. When flow is constant, it should be liberal. If there is not a liberal flow at 1,000 RPM in Neutral, low pump capacity, main circuit system leakage, stuck converter charge relief valve, or cooler system restriction is indicated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Page 1117 Fluid - A/T: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. FLUID CHANGE NOTE: Normal maintenance and lubrication requirements do not necessitate periodic fluid changes. If a major failure has occurred in the transmission, it will have to be removed for service. At that time the converter, transmission cooler, and cooler lines must be flushed to remove any dirt. If vehicle accumulates 5,000 or more miles per month or is used in continuous stop and go service, change fluid every 30,000 miles as described. Procedures for partial drain and refill, due to in-vehicle service operation, are as follows: 1. Loosen pan attaching bolts and drain fluid. 2. Remove and thoroughly clean pan and screen, discarding pan gasket. 3. Place new gasket on pan and install pan on transmission. 4. Add 3 quarts of fluid to transmission through filler tube. 5. Check fluid level following room normal operating checking procedures. NOTE: When filling a dry transmission and converter, approximate retill capacity is 9 quarts. Make final check using normal operating temperature checking procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1122 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1123 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Five-Speed Manual Overdrive Transmission (Ford Manual Transmission) Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX (E4XZ-19582-B) or Equivalent ..... .............................................................................................................................................................. .............. 5.6 Pints (US) (2.65 Liters) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1126 Fluid - M/T: Fluid Type Specifications Five-Speed Manual Overdrive Transmission (Ford Manual Transmission) Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX (E4XZ-19582-B) or Equivalent ..... .............................................................................................................................................................. .............. 5.6 Pints (US) (2.65 Liters) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Differential Fluid Types And Capacities Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1131 Fluid - Differential: Fluid Type Specifications Key to Lubrication Abbreviations KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease LS Steering Gear Lubricant MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Rear Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1132 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Refill (3.0L) .......................................................................................................................................... ........................................................... 3.5 Qts.(3.3L) Refill (2.3L, 4.0L) ................................................................................................................................. .......................................................... 4.0 Qts.(3.8L) Note: Capacity shown without filter. When replacing filter, additional oil may be needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1139 Engine Oil: Fluid Type Specifications Motorcraft Motor Oil 5W30 Super Premium ......................................................................................................................... ESE-M2C153-E and API SG Motorcraft Motor Oil 10W30 Super Premium ....................................................................................................................... ESE-M2C153-E and API SG Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1144 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1145 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1146 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1147 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1148 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1149 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1150 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1151 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1152 Refrigerant: Technical Service Bulletins A/C - Release of R134a Fluorescent Dye Article No. 94-26-6 12/26/94 AIR CONDITIONING - RELEASE OF R-134A FLUORESCENT TRACER DYE - FOR 1992 TAURUS, R-134A VEHICLES ONLY - SERVICE TIP FORD: 1992-95 TAURUS 1994-95 ASPIRE, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, THUNDERBIRD 1994 TEMPO 1995 CONTOUR LINCOLN-MERCURY: 1993-95 MARK VIII 1994-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994 CAPRI, TOPAZ 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: Ford Motor Company has approved an R-134a Fluorescent Tracer Dye (Rotunda Part, 112-ROO40) for use in checking R-134a A/C systems for refrigerant leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1153 ACTION: When leak checking an R-134a system, install the 112-R0040 dye using a Rotunda Dye lnjector (164-R2610). Use the procedures in Figure 1 when leak checking. This method of leak detection is an approved alternate to electronic leak detection and vacuum decay leak detection. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacity ............................................................................................................... ...................................................................... 26 oz Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1156 Refrigerant: Fluid Type Specifications R-134a Hydrofluorocarbon(HFC) ................................................................................................................................. WSH-M17B19A Motorcraft YN-11 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: Customer Interest A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 1165 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 1171 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: All Technical Service Bulletins A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 1176 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 94156 > Jul > 94 > A/C Compressor - Service Tips Refrigerant Oil: All Technical Service Bulletins A/C Compressor - Service Tips Article No. 94-15-6 07/27/94 AIR CONDITIONING - FS-10 AND FX-15 COMPRESSORS - SERVICE TIPS FORD: 1988-94 CROWN VICTORIA, ESCORT, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 MARK VII 1988-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-94 TRACER 1993-94 MARK VIII LIGHT TRUCK: 1988-90 BRONCO II 1988-94 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: FS-10 service compressors built between 1/1/93 and 9/30/93 were built with 7 oz. of oil. These compressors have a white label and are labeled to be compatible with either R-12 or R-134a. These compressors contain either PAG oil or Mineral oil and should be used only in the proper systems. ACTION: Refer to the chart to determine the type of oil that is in each service compressor. NOTE: BE SURE TO CHOOSE THE COMPRESSOR THAT HAS THE CORRECT OIL FOR THE SYSTEM BEING SERVICED. NOTE: FS-10 COMPRESSORS BUILT AFTER 9/30/93 ARE NOT FILLED WITH OIL AND HAVE A YELLOW LABEL. THESE COMPRESSORS REQUIRE THE CORRECT AMOUNT OF EITHER MINERAL OIL OR PAG OIL DEPENDING ON THE SYSTEM BEING SERVICED. NOTE: FX-15 SERVICE COMPRESSORS BUILT BEFORE 1/1/93 ARE FILLED WITH MINERAL OIL AND ARE ONLY COMPATIBLE WITH R-12 SYSTEMS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 1190 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 94156 > Jul > 94 > A/C Compressor - Service Tips Refrigerant Oil: All Technical Service Bulletins A/C Compressor - Service Tips Article No. 94-15-6 07/27/94 AIR CONDITIONING - FS-10 AND FX-15 COMPRESSORS - SERVICE TIPS FORD: 1988-94 CROWN VICTORIA, ESCORT, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 MARK VII 1988-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-94 TRACER 1993-94 MARK VIII LIGHT TRUCK: 1988-90 BRONCO II 1988-94 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: FS-10 service compressors built between 1/1/93 and 9/30/93 were built with 7 oz. of oil. These compressors have a white label and are labeled to be compatible with either R-12 or R-134a. These compressors contain either PAG oil or Mineral oil and should be used only in the proper systems. ACTION: Refer to the chart to determine the type of oil that is in each service compressor. NOTE: BE SURE TO CHOOSE THE COMPRESSOR THAT HAS THE CORRECT OIL FOR THE SYSTEM BEING SERVICED. NOTE: FS-10 COMPRESSORS BUILT AFTER 9/30/93 ARE NOT FILLED WITH OIL AND HAVE A YELLOW LABEL. THESE COMPRESSORS REQUIRE THE CORRECT AMOUNT OF EITHER MINERAL OIL OR PAG OIL DEPENDING ON THE SYSTEM BEING SERVICED. NOTE: FX-15 SERVICE COMPRESSORS BUILT BEFORE 1/1/93 ARE FILLED WITH MINERAL OIL AND ARE ONLY COMPATIBLE WITH R-12 SYSTEMS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil System Capacity ......................................................................................................... ......................................................................... 7.0 oz Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1201 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ..................................................................... PAG [1] [1] Motorcraft YN-12b or equivalent Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Description and Operation Brake Bleeding: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the lines and cause spongy pedal action. This requires the bleeding of the hydraulic system after it has been properly connected to be sure all air is expelled from the brake cylinders and lines. The hydraulic system can be bled manually or with pressure bleeding equipment such as Rotunda(r) brake bleeder 104-00064 or equivalent. Bleed one brake cylinder at a time. Start the bleeding at the right rear brake wheel cylinder and then the left rear wheel brake cylinder. Then proceed to bleed the front brakes, starting with the right front brake and finish bleeding on the left front brake. Keep the brake master cylinder reservoir filled with the specified Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA (ESA-M6C25-A) or equivalent. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoirs filled with the specified brake fluid. Never reuse the fluid that has been drained from the hydraulic system. NOTE: Bleed the primary and secondary hydraulic brake systems separately. Master Cylinder Reservoir 1. On the brake master cylinder reservoir, loosen the master cylinder-to-hydraulic line fittings. 2. Wrap a shop cloth around the tubing below the fitting to absorb escaping brake fluid. 3. Push the brake pedal down slowly to the floor of the cab. This will force air trapped in the brake master cylinder reservoir to escape at the fitting. 4. Hold the brake pedal down and tighten the fitting. Release the brake pedal. NOTE: Do not release the brake pedal until the fitting is tightened or air will re-enter the brake master cylinder reservoir. 5. Repeat this procedure until air ceases to escape at the fitting. Wheel Cylinder Bleeding 6. Place a box wrench on the bleeder fitting on the rear anti-lock brake system valve. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly around the bleeder fitting. a. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. b. Slowly press the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. c. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 7. Place a box wrench on the right brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1207 around the bleeder fitting. 8. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. 9. Slowly push the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. 10. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 11. Repeat this procedure at the left brake wheel cylinder on the opposite side. Refill the brake master cylinder reservoir after each wheel cylinder is bled. 12. Bleed the front brakes starting with the right front brake and then the left front brake as described in Steps 7-11 of this procedure. 13. When the bleeding operation is complete, fill the brake master cylinder to the maximum level line of the brake master cylinder reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1208 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes, get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Be sure the bleeder tank contains enough specified brake fluid (Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA [ESA-M6C25-A] or equivalent), to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi) of air pressure. Never exceed 345 kPa (50 psi) of pressure. Never re-use brake fluid that has been drained from the hydraulic system. NOTE: Bleed the longest line first. 1. Clean all dirt from the brake master cylinder filler cap. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 2. Remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool, Rotunda Brake Bleeder model 104-00064 or equivalent to the brake master cylinder, and attach the bleeder tank hose to the fitting on the adapter. 3. Place a 3/8-inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly around the bleeder fitting. 4. open the valve on the bleeder tank to admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube on the wheel cylinder in a partially filled container of clean brake fluid. Loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. Move on to the left rear, the right front, and finally left front. 7. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 8. Remove the pressure bleeder adapter tool. Fill the brake master cylinder reservoirs to the maximum level line. Install the brake master cylinder filler cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1209 Brake Bleeding: Service and Repair Priming Brake System NOTE: When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir (2K478), and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b. On the brake master cylinder, loosen the rearmost brake tube fitting with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fitting. 7. If any of the brake tubes, disc brake calipers, or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. 8. To gravity bleed the brake system: a. Fill the brake master cylinder with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. b. Loosen both of the rear bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws to 7-9 Nm (62-79 in- lb). Tighten rear caliper bleed screws to 17-24 Nm (13-17 ft-lb). d. One at a time, loosen the front caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the front caliper bleeder screws to 17-24 Nm (13-17 ft-lb). 9. After the brake system has been primed, bleed the brake system at each wheel. NOTE: Keep the brake master cylinder reservoir filled with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1210 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: The anti-lock brake system must be bled in two steps. 1. The brake master cylinder and Hydraulic Control Unit must be bled using Anti-lock Brake Adapter T90P-50-ALA and Jumper T93T-50-ALA. If this procedure is not followed, air will be trapped in the HCU which eventually leads to a spongy brake pedal. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1. T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2. -- Bleed/Harness Selector (Part of T90P-50-ALA) 3. -- Green "Motor On" Lamp (Part of T90-50-ALA) 4. -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5. -- Valve Button (Part of T90P-50-ALA) 6. -- Abort Button (Part of T90P-50-ALA) 7. -- Motor Start Button (Part of T90P-50-ALA) 2. To bleed the brake master cylinder and HCU, disconnect the 40-pin plug from the Electronic Control Unit and install the anti-lock brake adapter to the wire harness 40-pin plug. a. Place the bleed/harness selector in bleed position. b. Turn the ignition switch (11572) ON. At this point the red OFF indicator on the adapter should turn on. c. Push the motor button on the adapter down. This starts the pump motor. The red OFF indicator turns off and the green ON indicator turns on. The pump motor will run for 60 seconds once the motor button is pushed (you do not need to hold the button down). If the pump motor is to be turned off for any reason before this 60 seconds has elapsed, push the abort button and the pump motor will turn off. d. After the first 20 seconds have passed, push and hold the valve button for 20 seconds. This bleeds any trapped air from the brake master cylinder and HCU. e. The pump continues to run for an additional 20 seconds after the valve button is released. 3. Bleed the brake lines in the following order: ^ Right rear ^ Left front ^ Left rear ^ Right front Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 Circuit Breaker: Electrical Diagrams Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Power Distribution Circuit-To-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1234 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1235 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1236 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1237 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1238 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1239 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Daytime Running Lamps ........................................................................................ .................................................................................................... Fuse 5 Dome/Courtesy Lamp ......... .............................................................................................................................................................. .......................... Fuse 1 Electronic Shift Control Module .................................................................... ............................................................................................................. Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ............................................. Fuse 7 Headlamp Switch ....................................................................... ............................................................................................................................... Fuse 11 Heated Backlite ................................................................................................................................................ ........................................................... Fuse 5 Heated Oxygen Sensor #1 .......................................... ............................................................................................................................................... Fuse 18 Heated Oxygen Sensor #2 .................................................................................................................. ....................................................................... Fuse 18 Heater and A/C Control Assembly ................. ............................................................................................................................................................ Fuse 9 Horn Relay ............................................................................................................................... ................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................. Fuse 8 Instrument Cluster ................................. .............................................................................................................................................................. ........ Fuse 7 Instrument Panel Illumination Lamps ............................................................................. .......................................................................................... Fuse 13 Liftgate Wiper Motor and Switch . .............................................................................................................................................................. .............. Fuse 17 Liftgate Wiper/Washer Switch ................................................................................ .................................................................................................. Fuse 17 Low Oil Level Relay ............ .............................................................................................................................................................. ......................... Fuse 7 Parking/License Lamps ................................................................................. ............................................................................................................ Fuse 10 Power Mirror (Two Door Only) ........................................................................................................................................... ...................................... Fuse 1 Premium Radio Amplifier .................................................................. ....................................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ..................................... .................................................................................................................................................. Fuse 10 Automatic Day/Night Mirrors ........................................................................................................... ........................................................................ Fuse 17 Backup Lamps .............................................. .............................................................................................................................................................. Fuse 5 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................................................................................... ................................................................................................ Fuse 4 Courtesy Lamp Switches ........ .............................................................................................................................................................. ...................... Fuse 1 Daytime Running Lamps .................................................................................. .......................................................................................................... Fuse 5 Dome/Courtesy Lamp ... .............................................................................................................................................................. ................................ Fuse 1 Electronic Shift Control Module .............................................................. ................................................................................................................. Fuse 17 Electronic Shift Control Module .................................................................................................................................... ............................................. Fuse 7 Electronic Shift Control Switch .................................................. .............................................................................................................................. Fuse 17 Electronic Shift Control Switch ............................................................................................................................. ..................................................... Fuse 7 Headlamp Switch ............................................................... ......................................................................................................................................... Fuse 1 Headlamp Switch ................................................................................................................................. ..................................................................... Fuse 11 Heated Backlite ............................................... ............................................................................................................................................................ Fuse 5 Heated Mirrors ......................................................................................................................... ................................................................................... Fuse 7 Heated Oxygen Sensor #1 .................. .............................................................................................................................................................. ......... Fuse 18 Heated Oxygen Sensor #2 .......................................................................................... ............................................................................................... Fuse 18 Heated Rear Window ............ .............................................................................................................................................................. ........................ Fuse 5 Heater and A/C Control Assembly .................................................................. ........................................................................................................... Fuse 9 Horn Relay ................... .............................................................................................................................................................. ................................. Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 8 Instrument Cluster .............................................................................. ......................................................................................................................... Fuse 1 Instrument Cluster ................................................................................................................................................. .................................................... Fuse 17 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. ........ Fuse 17 Low Oil Level Relay ...................................................................................................... ............................................................................................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Overhead Console .... .............................................................................................................................................................. ..................................... Fuse 5 Parking/License Lamps ..................................................................... ........................................................................................................................ Fuse 10 Power Mirror (Two Door Only) .................................................................................................................................. ............................................... Fuse 1 Premium Radio Amplifier ......................................................... ................................................................................................................................ Fuse 16 Radio Memory (Power supplied through ........................................................................................................ ............................................................ Fuse 2 Radio Memory ............................................................ ................................................................................................................................................ Fuse 1 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 1 Remote Keyless Entry Module ........................ ........................................................................................................................................................... Fuse 6 Speed Control Amplifier ........................................................................................................... .................................................................................. Fuse 6 Stereo Radio and Tape Player ............. .............................................................................................................................................................. ........ Fuse 11 Stop/Hazard Lamps ...................................................................................................... .............................................................................................. Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ........................................................................... ............................................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ...................................................... .................................................................................................................................. Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................. ........................................................... Fuse 5 Turn Lamps ................................................................. ................................................................................................................................................ Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1258 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1259 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1260 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1261 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1262 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1263 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1264 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1265 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1266 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1267 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1268 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1269 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1270 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1271 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1272 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1273 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1274 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1275 Anti-Theft Controller Module ................................................................................................................ ..................................................................... Fuse 6 Autolamps .......................................................... ......................................................................................................................................................... Fuse 2 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch .......................... .............................................................................................................................................................. ........ Fuse 3 Cigar Lighter ................................................................................................................... ............................................................................................ Fuse 3 Courtesy Lamps ......................... .............................................................................................................................................................. ................... Fuse 2 Daytime Running Lamp Module .......................................................................... ..................................................................................................... Fuse 17 Dimmer Flash to Pass Switch .................................................................................................................................................. ................................... Fuse 3 Electronic Shift Control Module ........................................................... ...................................................................................................................... Fuse 7 Fog Lamp Relay .............................................................................................................................................................. .......................................... Fuse 15 Fuel Pump Relay ........................................................................ ............................................................................................................................... Fuse 18 Hazard Flasher ................................................................................................................................................. ........................................................... Fuse 3 Headlamps .................................................................. ................................................................................................................................................ Fuse 2 Heated Rear Window Switch ............................................................................................................... ..................................................................... Fuse 11 Horn ................................................................. ........................................................................................................................................................... Fuse 3 Ignition Switch ......................................................................................................................... .................................................................................. Fuse 1 LH Stop/Turn Signal Relay ................... .............................................................................................................................................................. ..... Fuse 19 Memory Seat Module ...................................................................................................... ........................................................................................... Fuse 8 PCM Power Relay ....................... .............................................................................................................................................................. ............... Fuse 14 PCM Power Relay ................................................................................................. ..................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................................. ...................................... Fuse 2 Power Bolster ................................................................................... .......................................................................................................................... Fuse 8 Power Door Locks ................................................................................................................................................... ................................................... Fuse 6 Power Lumbar ..................................................................... ....................................................................................................................................... Fuse 8 Power Mirrors ...................................................................................................................................... ....................................................................... Fuse 6 Power Seats .................................................... ............................................................................................................................................................. Fuse 8 Powertrain Control Module ...................................................................................................... .................................................................................. Fuse 4 Premium Sound/JBL Amplifier .............. .............................................................................................................................................................. ...... Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1276 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1277 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1278 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1279 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1280 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1281 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1282 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1283 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1284 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1285 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1286 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1287 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1288 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1289 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1290 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1291 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1292 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1293 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Component Locations The fuse panel is located behind the Lower Left Hand side of the Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1299 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1300 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1301 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1302 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1303 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1304 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1305 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1306 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Anti-Theft Controller Module .......................................................................................... ........................................................................................... Fuse 6 Autolamps .................................... .............................................................................................................................................................. ................. Fuse 2 Blower Motor Relay ............................................................................................... .................................................................................................... Fuse 5 Brake ON/OFF Switch ........ .............................................................................................................................................................. .......................... Fuse 3 Cigar Lighter ................................................................................................. .............................................................................................................. Fuse 3 Courtesy Lamps ....... .............................................................................................................................................................. ..................................... Fuse 2 Daytime Running Lamp Module ........................................................ ....................................................................................................................... Fuse 17 Dimmer Flash to Pass Switch ..................................................................................................................................... ................................................ Fuse 3 Electronic Shift Control Module .............................................. ................................................................................................................................... Fuse 7 Fog Lamp Relay ......................................................................................................................................... ............................................................... Fuse 15 Fuel Pump Relay ................................................... .................................................................................................................................................... Fuse 18 Hazard Flasher ............................................................................................................................... ............................................................................. Fuse 3 Headlamps ................................................ .............................................................................................................................................................. .... Fuse 2 Heated Rear Window Switch .............................................................................................. ...................................................................................... Fuse 11 Horn ................................................ .............................................................................................................................................................. .............. Fuse 3 Ignition Switch .......................................................................................................... ................................................................................................. Fuse 1 LH Stop/Turn Signal Relay .... .............................................................................................................................................................. .................... Fuse 19 Memory Seat Module ....................................................................................... .......................................................................................................... Fuse 8 PCM Power Relay ........ .............................................................................................................................................................. .............................. Fuse 14 PCM Power Relay .................................................................................. .................................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................... .................................................... Fuse 2 Power Bolster ..................................................................... ........................................................................................................................................ Fuse 8 Power Door Locks ............................................................................................................................... ....................................................................... Fuse 6 Power Lumbar ................................................. ........................................................................................................................................................... Fuse 8 Power Mirrors .......................................................................................................................... ................................................................................... Fuse 6 Power Seats ........................................ .............................................................................................................................................................. ........... Fuse 8 Powertrain Control Module .......................................................................................... .............................................................................................. Fuse 4 Premium Sound/JBL Amplifier .. .............................................................................................................................................................. .................. Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1307 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1308 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1309 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1310 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1311 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1312 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1313 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1314 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1315 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1316 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1317 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1318 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1319 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1320 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1321 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1322 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1323 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1324 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1325 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1326 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1327 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1328 Power Distribution Box Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1329 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1330 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1331 Power Distribution Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1332 Daytime Running Lamps ..................................................................................................................... ....................................................................... Fuse 5 Dome/Courtesy Lamp ...................................... ........................................................................................................................................................... Fuse 1 Electronic Shift Control Module ............................................................................................... .................................................................................. Fuse 7 Electronic Shift Control Switch ............. .............................................................................................................................................................. ....... Fuse 7 Headlamp Switch ............................................................................................................. ......................................................................................... Fuse 11 Heated Backlite ........................... .............................................................................................................................................................. .................. Fuse 5 Heated Oxygen Sensor #1 ................................................................................... ...................................................................................................... Fuse 18 Heated Oxygen Sensor #2 ......................................................................................................................................................... ................................ Fuse 18 Heater and A/C Control Assembly ........................................................ ..................................................................................................................... Fuse 9 Horn Relay ......... .............................................................................................................................................................. ........................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................................. ...................................................... Fuse 8 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. .......... Fuse 7 Parking/License Lamps ................................................................................................ ............................................................................................. Fuse 10 Power Mirror (Two Door Only) . .............................................................................................................................................................. .................. Fuse 1 Premium Radio Amplifier ...................................................................................... ................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1333 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1334 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1335 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1336 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1337 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1338 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1339 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1340 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1341 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Cigar Lighter ........................................................................................................................................ ..................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 10 Automatic Day/Night Mirrors ................. .............................................................................................................................................................. .... Fuse 17 Backup Lamps .................................................................................................................. .......................................................................................... Fuse 5 Blower Motor Relay ...................... .............................................................................................................................................................. ............... Fuse 5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................... .............................................................................................................................................................. .. Fuse 4 Courtesy Lamp Switches ...................................................................................................... ...................................................................................... Fuse 1 Daytime Running Lamps .................. .............................................................................................................................................................. ............ Fuse 5 Dome/Courtesy Lamp ................................................................................................. ................................................................................................ Fuse 1 Electronic Shift Control Module ................................................................................................................................................. .............................. Fuse 17 Electronic Shift Control Module .............................................................. ................................................................................................................... Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ........................................... Fuse 17 Electronic Shift Control Switch .................................................. ................................................................................................................................ Fuse 7 Headlamp Switch .................................................................................................................................................. ...................................................... Fuse 1 Headlamp Switch .............................................................. ........................................................................................................................................ Fuse 11 Heated Backlite ................................................................................................................................... ........................................................................ Fuse 5 Heated Mirrors ................................................ ............................................................................................................................................................ Fuse 7 Heated Oxygen Sensor #1 ...................................................................................................... ................................................................................... Fuse 18 Heated Oxygen Sensor #2 ................ .............................................................................................................................................................. ........... Fuse 18 Heated Rear Window ................................................................................................ .................................................................................................. Fuse 5 Heater and A/C Control Assembly ............................................................................................................................................. ................................ Fuse 9 Horn Relay .............................................................................................. .................................................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 8 Instrument Cluster ................................................................................................................................................. ...................................................... Fuse 1 Instrument Cluster ............................................................ ......................................................................................................................................... Fuse 17 Instrument Cluster ............................................................................................................................... ........................................................................ Fuse 7 Instrument Panel Illumination Lamps ............. .......................................................................................................................................................... Fuse 13 Liftgate Wiper Motor and Switch ............................................................................................ ................................................................................. Fuse 17 Liftgate Wiper/Washer Switch ............. .............................................................................................................................................................. ....... Fuse 17 Low Oil Level Relay ....................................................................................................... .......................................................................................... Fuse 17 Low Oil Level Relay .................... .............................................................................................................................................................. ................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 1 Overhead Console .............................................................................. ......................................................................................................................... Fuse 5 Parking/License Lamps ....................................................................................................................... ...................................................................... Fuse 10 Power Mirror (Two Door Only) ........................ ......................................................................................................................................................... Fuse 1 Premium Radio Amplifier ......................................................................................................... ................................................................................ Fuse 16 Radio Memory (Power supplied through ................................................................................................................................................ .................... Fuse 2 Radio Memory .................................................................................................... ........................................................................................................ Fuse 1 Remote Keyless Entry Module ................................................................................................................................................. .................................. Fuse 1 Remote Keyless Entry Module ............................................................. ...................................................................................................................... Fuse 6 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................................... ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 Fusible Link: Electrical Diagrams Fuse Link - protects the following circuits: - From the alternator to the battery and the Power Distribution Box Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1385 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Malfunction Indicator Lamp: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 1391 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Page 1392 Malfunction Indicator Lamp: Description and Operation PURPOSE To alert the vehicle operator of a malfunction in the electronic engine control system. OPERATION The Malfunction Indicator will light with the ignition switch in the ON position prior to cranking, and goes out when the engine starts. If a fault develops, the powertrain control module will turn the indicator ON. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Description and Operation > Page 1396 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1406 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1407 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1408 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1409 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1410 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1411 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1412 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1413 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1414 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1415 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1420 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1421 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1422 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1423 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1424 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1425 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1426 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1431 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1432 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1433 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1434 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1435 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1437 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1443 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1444 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1445 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1446 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1447 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1448 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1449 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1450 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1451 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 1452 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1457 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1458 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1459 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1460 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1461 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1462 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 1463 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1468 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1469 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1470 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1471 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1472 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1473 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 1474 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments REMOVAL AND INSTALLATION 1. Raise and support front of vehicle. 2. Remove wheel cover, grease cap, cotter pin and locknut. 3. Loosen adjusting nut 3 turns, then lock wheel assembly in and out several times to push brake shoe and linings away from rotor. 4. Torque adjusting nut to 17-25 ft lb while rotating wheel assembly. 5. Loosen adjusting nut 1/2 turn, then retorque to 18-20 inch lbs. 6. Install locknut and cotter pin. 7. Ensure wheel assembly rotates smoothly, then reinstall grease cap and wheel cover and lower vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips Wheel Hub (Locking): Technical Service Bulletins Automatic Hublock - Diagnosis/Service Tips Article No. 95-5-18 03/13/95 ^ LOCK HUBS - 4WD - AUTOMATIC HUBLOCK INFORMATION - SERVICE TIPS ^ FOUR-WHEEL DRIVE (4WD) - AUTOMATIC LOCK HUB DIAGNOSIS LIGHT TRUCK: 1983-90 BRONCO II 1983-95 RANGER 1991-94 EXPLORER ISSUE: 4X4 system diagnosis can be difficult at times due to system complexities. ACTION: For general system operation and diagnosis: Refer to TSB Article No. 92-1-8. For specific automatic lock hub diagnosis and service: Refer to this article. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 1482 HUBLOCK DIAGNOSTICS WHEEL END CONTAMINATION: ^ All compact vehicle hublocks have an O-ring seal between the hublock and wheel hub to prevent contamination. Whenever the hublock is removed, the 0-ring seal should be checked for damage. ^ If contamination is found in the wheel end, the path must be determined and corrected. Path possibilities are through the hublock seal, the wheel bearing seals or the axle spindle seals. WHEEL END NOISE (BUZZING) IN 4X2, AFTER UNLOCKING HUBS, SHORTLY AFTER FOUR-WHEEL DRIVE USAGE: ^ Noise concerns in two-wheel drive shortly after shifting from four-wheel drive and unlocking hubs, can occur if one of the hublocks fails to disengage. As the vehicle moves forward, the one (1) hublock that has failed to disengage will rotate its axle shaft through the differential and attempt to rotate the other axle shaft in the opposite direction. This is called differential motoring torque. As this torque attempts to turn the other axle shaft through the differential gears, that shaft's hublock will attempt to engage which will result in a ratcheting or buzzing noise. ^ This type of noise concern is usually found on axles that have incorrect front axle differential lubricant or very few 4X4 miles on them. ^ Verify that the front axle differential lubricant is F1TZ-19580-A. If incorrect lubricant is detected, extract the old lubricant using a suction gun. NOTE: BREAKING THE CARRIER SEAL IS NOT A RECOMMENDED METHOD OF EXTRACTING THE LUBRICANT. 1. Refill the front axle with 56 oz (1.66 L) of lubricant F1TZ-19580-A using a suction gun. 2. As the front axle accumulates 100-200 miles (161-322 km) of locked hublock operation, the axle will break-in, thus reducing the amount of differential motoring torque significantly. 3. If a front axle requires breaking in, refer to the Front Axle Break-In Procedure in this article. 4. If the front axle has been broken-in and the differential lubricant is F1TZ-19580-A, however, a wheel end noise (buzzing) in 4X2 is still experienced shortly after four-wheel drive usage. It is advised that the hublock which is not ratcheting be replaced as it is not disengaging correctly. When this condition occurs on any 4X4 Ranger, Explorer, or Bronco II, built from 10/89 through model year 1993, it is advised that both hublocks be replaced as the ratcheting hub is likely to become damaged. FRONT AXLE BREAK-IN PROCEDURE: ^ To break-in the front axle, engage four-wheel drive and then shift out of it without disengaging the hublocks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 1483 ^ Thereafter, continue to drive the vehicle with locked hublocks until 100-200 miles (161-322 km) are accumulated. This will break-in the axle. Should the vehicle be backed up during this time period, the hublocks will disengage and will have to be locked again by repeating the engagement procedure. WHEEL END NOISE (RATCHETING) IN 4X2 AND HUBS UNLOCKED: ^ This condition could occur during turns or when the suspension is stroked. It is more prevalent in cold weather, with new front axles. It is usually caused by high motoring torque at the axle shafts or by incorrect axle lubrication. ^ Verify that axle lubrication is F1TZ-19580-A. If the front axle is not broken-in, 100-200 4X4 miles (161-322 km), proceed to do so following the outlined front axle break-in procedure in the Hublock Diagnostics section of this TSB article. WHEEL END NOISE (BUZZING) WHILE ENGAGING 4X4 (TOUCH DRIVE) WHILE MOVING: ^ Refer to TSB Article No. 91-15-10. POPPING/BANGING SOUND WHILE IN 4X4: ^ If the system slips under load, find what has broken or is slipping. To locate where slip is taking place, put marks at various possible slip points (Figure 1). Test drive the vehicle, then check to see if marks at different points are still in the same relationship to each other. This will help you determine where the slippage is taking place or where to look for broken parts, if any. ^ On vehicles with automatic hubs, find a place where you can do your test, mark the components, then drive without backing up. Stop and check the marks to see if they are in the same relationship to each other. If you back up before checking your marks, the hubs may reindex and not reveal the problem. ^ Reindex component should be serviced. INSTALLATION PROCEDURE 1. Remove old hublock; remove key from bearing retainer nut and then remove nut. 2. If replacing a manual hublock with an automatic hublock, also remove the three-piece wheel bearing nut assembly. 3. Remove the new wheel bearing retaining nut from the cam assembly and install on the threaded spindle. 4. Using Hex Locknut Wrench (T70T-4252-B), torque the wheel bearing retainer nut to 47 N-m (35 lb.ft.) while rotating the wheel assembly. Back nut off 1/4 turn and retighten to 1.8 N-m (16 lb.in.) of torque. 5. Align scallop of the wheel bearing retaining nut with the center of the spindle keyway by advancing the nut clockwise. 6. Install the retaining key into the spindle keyway. With the garter spring inboard, align the key on the cam assembly with the keyway on the spindle. 7. Firmly press the cam assembly on the wheel bearing retaining nut. CAUTION: DO NOT PACK THE HUBLOCK WITH GREASE. TOO MUCH GREASE WILL CAUSE IMPROPER HUBLOCK OPERATION AND MAY DAMAGE THE HUBLOCK. 8. For Ranger and Bronco II, model years 1983-90 (through build date 10/4/89), using the DANA 28 Axle, install the thrust washer set onto the axle: a. First, the plain steel washer. b. Second, the needle bearing. c. Last, the spline washer. 9. For model years 1990-94 (begin build date 10/5/89), DANA 35 Axle, install the one-piece spline washer. Install the "C" clip into the axle groove. It may be necessary to push the axle outboard from the inboard side of the knuckle. 10. For 1995 Ranger, install the thrust washer onto the axle: a. First, the plain steel thrust washer. b. Second, the plastic unsplined thrust washer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 1484 c. Last, the steel spline thrust washer. CAUTION: ENSURE THE RETAINING RING OR "C" CLIP IS SEATED PROPERLY IN THE AXLE GROOVE FOR STEPS 8, 9, OR 10. 11. Check to ensure 0-ring seal on the flange face of the hublock body is not damaged and is properly positioned in its groove. 12. Install the hublock body assembly into the vehicle hub and rotor assembly. The hub may have to be rotated to line up the three (3) prongs of the cam follower (found internally to the hublock) with the cam assembly. 13. Install retainer flat nuts on wheel studs. NOTE: DO NOT FORCE THE HUBLOCK ASSEMBLY. IF THE BODY ASSEMBLY WILL NOT FIT, RECHECK THE ALIGNMENT OF ALL COMPONENTS. INSTALL SPEEDNUTS ON WHEEL LUGS TO RETAIN HUBLOCK. THEREAFTER, INSTALL THE WHEEL AND TORQUE THE LUG NUTS TO 136 N-m (100 LB.FT.) (FIGURE 2). HISTORY AND TIMING The Warn Automatic Hublock (Model M350) was used on the DANA 28 Axle (Bronco II and Ranger) from model years 1983-90 (through build date 10/4/89). The Warn Automatic Hublocks (Models M350A and M350B) were used on the DANA 35 Axle (Bronco II, Explorer and Ranger) for model years 1990-93 (begin build date 10/5/89). Starting with model year 1994 the Warn Automatic Hublock (Model M350C) used on the DANA 35 Axle (Explorer and Ranger) was introduced. The Model M350 is black and Model M350A, M350B and M350C are argent (white silver) in color. The Model M350 can only be replaced by Model M350 service parts. The M350C service kits should be used as replacements for the following: ^ M350A hublocks released 10/89 as model year 1990 running change. ^ M350B hublocks released 4/92 as model year 1992 late running change. ^ M350C hublocks released 8/93 as model year 1994 Job 1 change. When automatic hublock servicing is required for any Ranger, Explorer, or Bronco II built from 10/89 through model year 1993, it is advised that both hublocks be replaced. NOTE: IF AN M350A OR M350B HUBLOCK REQUIRES SERVICING, ALL THE HUBLOCK COMPONENTS MUST BE REMOVED AND REPLACED WITH SERVICE KIT F3TZ-3B396-B, WHICH ESSENTIALLY IS THE SERVICE KIT FOR THE M350C AUTOMATIC HUBLOCK. THE CAM ASSEMBLY OF THE M350A OR M35OB SHOULD NOT BE USED WITH AN M350C AUTOMATIC HUBLOCK BODY NOR SHOULD AN M350A OR M350B AUTOMATIC HUBLOCK BODY BE USED WITH AN M350C CAM ASSEMBLY. For model year 1994 (and beyond) 4X4 Rangers or Explorers, replace automatic hublocks in accordance with the automatic hublock Service Manual procedure and additional diagnostics procedure outlined in this TSB. IDENTIFYING AUTOMATIC HUBLOCK MODELS A stamped code found on the rear of the automatic hublock flange face can be used to identify the automatic hublock type, in addition to the model year summary described above. Examples of the three (3) different codes which correlate to the automatic hublock model type are outlined in the chart: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 1485 THE ABOVE PART APPLICATION CHART IS FOR 1983-90 (THROUGH BUILD DATE 10/4/89) BRONCO II, RANGER, DANA 28 AXLE, HUBLOCK MODEL M350: THE ABOVE PART APPLICATION CHART IS FOR: ^ 1990-95 Ranger (begin build date 10/5/89) ^ 1990 Bronco (begin build date 10/5/89 through end of production) ^ 1991-94 Explorer (through build date 11/18/94, DANA 35 Axle, Hublock Model M350C) OTHER APPLICABLE ARTICLES: 92-1-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 508000, 509000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1490 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1491 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines Towing Information: Technical Service Bulletins Vehicle - Towing Behind RVs Guidelines Article No. 98-5A-12 03/18/98 ^ BRAKES - WEIGHT LIMITATIONS FOR TOWING ^ RECREATIONAL VEHICLES - WEIGHT RATINGS FOR UNBRAKED TOWING LESS THAN GROSS COMBINATION WEIGHT RATING (GCWR) ^ TOWING BEHIND RECREATIONAL VEHICLES - RECOMMENDED GUIDELINES ^ TRANSAXLE/TRANSMISSION/TRANSFER CASE - VEHICLES TOWED BEHIND RECREATIONAL VEHICLES - RECOMMENDED TOWING GUIDELINES FORD: 1988-93 FESTIVA 1988-94 TEMPO 1989-96 PROBE, TAURUS SHO 1991-97 ESCORT 1994-96 ASPIRE LINCOLN-MERCURY: 1988-94 TOPAZ 1991-94 CAPRI 1991-97 TRACER LIGHT TRUCK: 1988-96 AEROSTAR, BRONCO, E-350, F SUPER DUTY, F-250, F-350, F-53 MOTORHOME, RANGER 1988-97 F-150 1991-96 EXPLORER 1997 MOUNTAINEER ISSUE: Many motorhome owners tow a vehicle when traveling. Improper techniques can "overload" the brake system of the tow vehicle or damage the drivetrain of the vehicle being towed. ACTION: Use the information and charts shown in this TSB article to properly match tow vehicle, towed vehicle and towing method. TOWING METHODS 1. TRAILER - The vehicle is loaded onto and secured to a trailer and simply acts as "secured" cargo. 2. DOLLY - The vehicle is "partially" loaded and partially towed. Either front or rear wheels are loaded and secured to a "towing dolly" and the other wheels roll on the road. 3. TOW BAR - All of the vehicle wheels roll on the pavement. The towed vehicle's steering column must be unlocked so that it can track correctly behind the tow vehicle. WEIGHT RATINGS AND BRAKES ^ GVWR (Gross Vehicle Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle, passengers and cargo ^ GCWR (Gross Combined Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle and the weight of the trailer or vehicle being towed, including all passengers and cargo ^ BRAKES - The motorhome brakes are designed and rated for the GVWR of that vehicle and will provide adequate braking for trailers and towing vehicles up to 680 kg (1500 lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 1496 CAUTION: SEPARATE AUXILIARY BRAKES ARE REQUIRED ON TRAILERS OR TOWED VEHICLES OVER 680 KG (1500 LBS). DO NOT CONNECT A TRAILER'S, DOLLY'S OR OTHER TOWED VEHICLE'S BRAKE SYSTEM TO THE TOWING VEHICLE'S BRAKE SYSTEM. TOWED VEHICLES 1. Trailer-towed - The vehicle should be loaded on the trailer in a manner to: a. achieve a trailer tongue load of 10-15% of total trailer weight, b. not exceed the trailer or hitch ratings and c. be securely tied down. 2. Dolly-towed - For front wheel drive vehicles, towing an automatic transaxle (ATX)-equipped vehicle behind another vehicle, such as a Recreational Vehicle (RV), requires that a front wheel dolly or trailer be used. NOTE: TEMPO ALL-WHEEL DRIVE MODELS MUST BE TRAILER-TOWED. DO NOT TOW THESE VEHICLES USING A TWO-WHEEL TOWING DOLLY. CAUTION: DO NOT TOW A VEHICLE WITH AN AUTOMATIC (ATX) TRANSAXLE WITH THE DRIVE WHEELS ON THE GROUND. DAMAGE TO THE TRANSAXLE MAY RESULT. 3. Tow Bar-towed - Vehicles which can be successfully towed with a tow bar are listed in the following chart. Additional vehicle-specific information follows the chart. ALL VEHICLES NOTE: DO NOT TOW ANY VEHICLE AT A SPEED FASTER THAN 88 KM/H (55 MPH). THE MAXIMUM TOWING DISTANCE (WHEN TOWED CORRECTLY) IS UNLIMITED. WARNING: NEVER USE A TOW BAR THAT ATTACHES ONLY TO THE BUMPER. MTX-EQUIPPED VEHICLES Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 1497 Towing a manual transaxle (MTX)-equipped vehicle with the drive wheels on the ground is acceptable only if the vehicle is towed in a forward direction. The parking brake must be released and the gear shift lever must be in Neutral. ^ For Aspire, Festiva, Escort and Tracer, the ignition key must be in the ACO position, the battery must be disconnected to eliminate battery drain, and the steering wheel must be unlocked ^ For Capri, the ignition key must be in the OFF position and the steering wheel unlocked ^ Refer to the specific vehicle Owner Guide for complete details CAUTION: TOWING MTX-EQUIPPED VEHICLES INCORRECTLY MAY RESULT IN TRANSAXLE DAMAGE. TRUCKS ^ The steering wheel must be unlocked by placing the ignition key in the OFF position ^ Manual transmission shift lever must be in Neutral ^ On 4X4 manual shift transfer cases, the shift lever must be in Neutral ^ 4X4 locking hubs (both manual and automatic) must be unlocked ^ Refer to the specific vehicle Owner Guide for complete details OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-24-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure ....................................................................................................................... PSI of lowest cylinder must be within 75% of highest Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Service and Repair Camshaft Gear/Sprocket REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1508 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1509 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1510 Camshaft Gear/Sprocket: Service and Repair Timing Gear REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1511 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1512 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > General Specifications Camshaft: Specifications General Specifications Allowable Lobe Lift Loss ...................................................................................................................... ....................................................................... 0.005 Theoretical Intake Valve Lift @ Zero Lash ........ ....................................................................................................................................................... 0.4024 Theoretical Exhaust Valve Lift @ Zero Lash ............................................................................................................................................................. 0.4024 Camshaft End Play .................................................................................................................. ......................................................................... 0.0008-0.004 Camshaft End Play Service Limit ........ .............................................................................................................................................................. .......... 0.009 Thrust Plate Thickness ................................................................................................... .................................................................................... 0.158-0.159 Journal-To-Bearing Clearance ... .............................................................................................................................................................. ........ 0.001-0.0026 Journal-To-Bearing Clearance Service Limit ........................................................ ....................................................................................................... 0.006 Bearing Outside Diameter . .............................................................................................................................................................. ................... 0.158-0.159 # 1 Journal Diameter ................................................................................... ................................................................................ 49.57-49.59 (1.951.1.952) # 2 Journal Diameter .............................................................................................................................................................. ..... 49.21-49.23 (1.937-1.938) # 3 Journal Diameter .......................................................................... ......................................................................................... 48.83-48.85 (1.922-1.923) # 4 Journal Diameter .............................................................................................................................................. ..................... 48.44-48.48 (1.907-1.908) Runout ................................................................................ .......................................................................................................... 0.127 (0.005) Max T.I.R. # 1 Bearing Inside Diameter .................................................................................................................................................... 49.635-49.655 (1.954.1.955) # 2 Bearing Inside Diameter ................................................................................................................................................... 49-255-49.275 (1.938-1.940) # 3 Bearing Inside Diameter ................................................................................................................................................... 48.750-48.768 (1.919-1.920) # 4 Bearing Inside Diameter ................................................................................................................................................... 48.875-48.895 (1.924-1.925) Front Bearing Location Distance In Inches That Front Edge Of Bearing Is Installed Below Front Face Of Cylinder Block ........................................................ 0.040-0.060 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > General Specifications > Page 1517 Camshaft: Specifications Torque Camshaft Thrust Plate Screws .............................................................................................................................................................. 9-13 Nm (7-10 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California Camshaft: Service and Repair California Removal Special service tool(s) required: Description and Tool Number Sensor Adjusting Wrench ... T94T-12270-A NOTE: It is necessary to replace oil pan gasket when removing and installing engine front cover. It is also necessary to remove the engine to remove the oil pan. 1. Remove engine. 2. Remove the upper and lower intake manifolds. 3. Remove the engine front cover. 4. Remove the oil pan. 5. Remove the hold-down clamp, screw and oil pump drive shaft from the rear of the cylinder block. NOTE: This vehicle has a Cylinder Identification Sensor (CID) sensor mounted on top of the oil pump drive assembly. Sensor Adjusting Wrench T94T-12270-A is designed for easy access to the hold-down clamp screw. 6. Disconnect the engine wiring harness connector at the CID sensor. 7. Remove the valve covers and rocker arm shaft assemblies. Lift out the push rods and place in a marked rack so they can be installed in the same location. 8. Remove the valve tappets. NOTE: Cylinder heads must be removed in order to remove the roller tappets. 9. Push the timing chain/belt tensioner into the retracted position, and install the retaining clip. Timing Chain Alignment Marks 10. Remove the camshaft sprocket attaching bolt and remove the camshaft sprocket from the camshaft. 11. Remove the camshaft thrust plate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1520 Assembly Of Camshaft Thrust Plate 12. Remove the camshaft carefully from the cylinder block, avoiding any damage to the camshaft bearings. Installation Special service tool(s) required: Description and Tool Number Sensor Adjusting Wrench ... T94T-12270-A Cylinder Identification Sensor (CID) Testing Wiring Harness ... T94T-50-B 1. Oil the camshaft journals and cam lobes with SAE 50 Service SG engine oil or equivalent meeting Ford specification ESE-M2C39-F. Insert the camshaft key. 2. Install the camshaft in the cylinder block, being careful to avoid damaging the bearing surfaces. 3. Install the thrust plate as shown so that it covers the main oil gallery. Tighten the attaching screws to 9-13 N-m (7-10 lb-ft). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1521 Aligning Timing Marks 4. Turn the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft sprocket, install the attaching bolt and tighten to 60-68 N.m (44-50 lb-ft). 5. Check the camshaft for correct end play. End play should be 0.065-0.165mm (0.025-0.064 inch). Remove the clip from the timing chain tensioner . 6. Position the valve tappets in their original locations. Apply SAE 50 Service SG or equivalent oil meeting Ford specification ESE-M2C39-F to both ends of the push rods. Install the push rods in the same locations as removed. 7. Install the intake manifolds. 8. Install the rocker arm shaft assemblies. Tighten the rocker arm stand bolts evenly and in sequence to 6-8 N.m (53-71 lb-in). 9. Install the valve covers. 10. Install the engine front cover as an assembly. Installing Oil Pump Drive 11. Install the oil pump drive, hold-down clamp and screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1522 View Of Camshaft Damper After Marking Damper 12. After performing Steps 1-11 above, rotate crankshaft until Top Dead Center (TDC) mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34mm (1.34 inches) COUNTERCLOCKWISE from the TDC mark. 13. Position No. 1 cylinder to TDC between the COMPRESSION and IGNITION stroke. (Both intake and exhaust valves must be CLOSED with TDC mark on vibration damper at pointer.) CID Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1523 14. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CID sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. Aligning CID Sensor Rotor NOTE: Normal CID sensor rotation is CLOCKWISE viewed from top of CID sensor. 15. Align the CID sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. 16. Position the sensor above its hole at RIGHT ANGLES to the block rear face. Sensor Vane Rotates Clockwise 17. Install the assembled CID sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane CLOCKWISE toward the center of the window. Sensor Vane Rotates Clockwise 18. ROTATE the CID sensor COUNTERCLOCKWISE. Install clamp and screw finger-tight. ROTATE the sensor back to its position at RIGHT ANGLES to the back of the block. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1524 CID Test Wiring Harness - T94T-50-B 19. Connect the CID Testing Wiring Harness T94T-50-B to the CID Sensor. 20. Connect the CID Testing Wiring Harness leads: a. RED harness wire to battery POSITIVE terminal. b. BLACK harness wire to battery NEGATIVE terminal. c. Voltmeter POSITIVE lead to harness' WHITE lead. d. Voltmeter NEGATIVE lead to battery NEGATIVE terminal. 21. ROTATE engine two revolutions to take up slack in timing chain and return No. 1 cylinder to its COMPRESSION stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CID sensor. 22. Verify that No. 1 cylinder is on its COMPRESSION stroke (both valves CLOSED). 23. Continue to ROTATE the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. NOTE: The voltmeter will register battery voltage whenever the CID sensor closes and makes a complete circuit. 24. While ROTATING the CID sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The final movement to set the CID sensor must be in a COUNTERCLOCKWISE direction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1525 25. ROTATE the CID sensor CLOCKWISE past the CID switching point (from 12 to O volts). 26. ROTATE the CID sensor COUNTERCLOCKWISE and STOP at the exact point the voltmeter switches from 0 to 12 volts. 27. Tighten the CID sensor hold-down bolt to 17-21 N.m (13-15 lb-ft) using Sensor Adjusting Wrench T94T-12270-A. 28. Disconnect the testing wiring harness and the voltmeter. 29. Install oil pan. 30. Install engine front cover. 31. Install engine. 32. Fill the cooling system to the proper level with the specified coolant and bleed the cooling system. 33. Fill the crankcase with the specified quantity and grade of oil. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 34. Connect the battery ground cable to the battery. 35. Run the engine at fast idle speed and check for coolant, fuel, vacuum and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1526 Camshaft: Service and Repair 49 State/Federal Fig. 6 Valve Timing Marks Fig. 7 Camshaft Thrust Plate Removal 1. Disconnect battery ground cable, then drain engine oil and cooling system. 2. Remove radiator, fan, spacer, drive belt and crankshaft damper. 3. Disconnect ignition wires from spark plugs. 4. Disconnect ignition coil and bracket assembly. 5. Remove clamp, bolt and oil pump drive from rear of engine block. 6. Remove alternator, then disconnect fuel lines. 7. Remove upper and lower intake manifolds as an assembly. 8. Remove rocker arm covers and rocker arm shafts as described in ROCKER ARM. 9. Remove pushrods in order so they can be installed in their original positions. 10. Remove roller tappets, then the oil pan. NOTE: Cylinder heads must be removed to remove the roller tappets. 11. Remove engine front cover and water pump as an assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > California > Page 1527 12. Push timing chain tensioner into retracted position, then install retaining clip, Fig. 6. 13. Remove camshaft sprocket attaching bolt, then the sprocket from camshaft. 14. Remove camshaft thrust plate, Fig. 7. 15. Carefully remove camshaft from block, avoiding any damage to camshaft bearings. 16. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1528 Camshaft: Tools and Equipment Tools Required: Description ........................................................................................................................................... ........................................................ Tool Number Sensor Adjusting Wrench ..................................... ...................................................................................................................................... T94T-12270-A Cylinder Identification Sensor (CID) Testing Wiring Harness ......................................................................................................................... T94T-50-B Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Valve Roller Tappet Diameter (Std.) ............................................................................................................................................................. 0.8742-0.8755 Valve Roller Tappet Clearance To Bore ........................................................................................................................................................ 0.0005-0.0022 Valve Roller Tappet Service Limit ............................................................................... ............................................................................................... 0.005 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Push Rod Runout (T.I.R. Max.) ........................................................................................................... ........................................................................ 0.020 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Diameter ................................................................................................................. ......................................................... 0.7799-O.7811 Rocker Arm Bore Diameter ................................................................................................................. .......................................................... 0.7830-0.7842 Rocker Arm Ratio ................................................................................................................................ ....................................................................... 1.46:1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 1538 Rocker Arm Assembly: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect ignition wires from spark plugs. 2. Disconnect fuel lines. 3. On left valve cover, remove upper intake manifold if required. 4. On right valve cover, remove ignition coil and bracket assembly. 5. Remove PCV valve hose and breather. 6. Remove rocker arm attaching screws and load distributor washers. Ensure washers are installed in their original position. 7. Remove rocker arm covers. It may be necessary to lightly tap covers with a plastic hammer to break seal. Fig. 4 Rocker Arm Shaft Assembly 8. Loosen rocker arm shaft attaching bolts in sequence two turns at a time, then remove rocker arm and shaft assembly. 9. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > General Specifications Connecting Rod: Specifications General Specifications Connecting Rod Pin Bore Diameter .................................................................................................... ........................................................... 0.9432-0.9439 Connecting Rod Crankshaft Bearing Bore Diameter ..................................................................................................................................... 2.2370-2.2378 Connecting Rod Crankshaft Bearing Bore Out-Of-Round ......................................................................................................................................... 0.0004 Connecting Rod Crankshaft Bearing Bore Taper ....................................................................................................................................................... 0.0004 Connecting Rod Length (Center-To-Center) ................................................................................................................................................. 5.1386-5.1413 Connecting Rod Alignment (Bore-To-Bore Max. Diff.), (Pin and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at ends of an 8" bar, 4" on each side of rod centerline.) Twist .................................................................................................................................................... .............................................................. 0.006 Bend ........................................................................... ........................................................................................................................................ 0.002 Connecting Rod Side Clearance (Assembled To Crank) Standard .............................................................................................................................................. ................................................. 0.0020-0.0106 Service Limit .............................................................. ........................................................................................................................................ 0.014 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > General Specifications > Page 1544 Connecting Rod: Specifications Tightening Specifications Connecting Rod Bearing Cap Nuts ................................................................................................................................................... 25-32 Nm (18-24 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1545 Connecting Rod: Service and Repair Fig. 8 Piston & Rod Assembly Ensure arrow on piston dome faces front of engine as shown, Fig. 8. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley/Damper/Front Oil Seal Coat crankshaft damper sealing surface with clean engine oil XO-5W30-QSP (ESE-M2C153-E) or equivalent SAE 5W-30 Service SG. - Apply RTV using Rotunda RTV Dispenser 071-00001 or equivalent to keyway of damper prior to installation. CAUTION: Do not drive damper on with a hammer. - Install damper using Crankshaft Damper Replacer T74P-6316-B. - Install damper attaching bolt and tighten to 40-50 Nm (30-37 ft-lb), then turn bolt an additional 80-90 degrees tighter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket Crankshaft Gear/Sprocket: Service and Repair Crankshaft Gear/Sprocket REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1551 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1552 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1553 Crankshaft Gear/Sprocket: Service and Repair Timing Gear REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1554 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1555 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearing Journal Diameter ........................................................................................................... .......................................................... 2.2433-2.2441 Main Bearing Out-Of-Round ............................. ........................................................................................................................................................ 0.0006 Main Bearing Taper Limit ........................................................................................................ .................................................................... 0.0006 per inch Main Bearing Journal Runout ............... .............................................................................................................................................................. 0.002 Max. Main Bearing Surface Finish (RMS) ................................................................................. ................................................................................................ 12 Main Bearing Runout Service Limit .............................................................................................................................................................. .............. 0.005 Main Bearing Desired Clearance to Crankshaft ............................................................................................................................................. 0.0008-0.0015 Main Bearing Allowable Clearance to Crankshaft ......................................................................................................................................... 0.0005-0.0019 Main Bearing Wall Thickness (Std.) Red ...................................................................................................................................................... 0.0707-0.0710 Main Bearing Wall Thickness (Std.) Blue ..................................................................................................................................................... 0.0711-0.0714 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > General Specifications Crankshaft: Specifications General Specifications Main Bearing Journal Diameter ........................................................................................................... .......................................................... 2.2433-2.2441 Main Bearing Out-Of-Round ............................. ........................................................................................................................................................ 0.0006 Main Bearing Taper Limit ........................................................................................................ .................................................................... 0.0006 per inch Main Bearing Journal Runout ............... .............................................................................................................................................................. 0.002 Max. Main Bearing Surface Finish (RMS) ................................................................................. ................................................................................................ 12 Main Bearing Runout Service Limit .............................................................................................................................................................. .............. 0.005 Thrust Bearing Journal Length ................................................................................... ....................................................................................... 1.039-1.041 Connecting Rod Journal Diameter .............................................................................................................................................. ................... 2.1252-2.1260 Connecting Rod Journal Out-Of-Round .................................................. ................................................................................................................... 0.0006 Connecting Rod Journal Taper Limit ........................................................................................................................................................... 0.0006 per inch Connecting Rod Journal Surface Finish (RMS) ....................................................................................................................................................... 12 Max. Main Bearing Thrust Face Surface Finish .................................................................................. ............................................................................. 2O Max. Main Bearing Runout (T.I.R.) .................. ........................................................................................................................................................... 0.001 Max. Crankshaft Free End Play ............................................................................................................................................... 0.05-0.32 mm (0.002-0.0125 inch) Connecting Rod Bearings Desired Clearance to Crankshaft .......................................................................................................................................................... 0.0003-0.0024 Allowable Clearance to Crankshaft ...................................................................................................................................................... 0.0005-0.0022 Connecting Rod Bearing Wall Thickness (Std.) Red ..................................................................................................................................... 0.0548-0.0552 Connecting Rod Bearing Wall Thickness (Std.) Blue .................................................................................................................................... 0.0552-0.0556 Main Bearing Desired Clearance to Crankshaft ............................................................................................................................................. 0.0008-0.0015 Main Bearing Allowable Clearance to Crankshaft ......................................................................................................................................... 0.0005-0.0019 Main Bearing Wall Thickness (Std.) Red ...................................................................................................................................................... 0.0707-0.0710 Main Bearing Wall Thickness (Std.) Blue ..................................................................................................................................................... 0.0711-0.0714 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > General Specifications > Page 1563 Crankshaft: Specifications Tightening Specifications Crankshaft Main Bearing Cap Bolts ............................................................................................................................................... 90-104 Nm (66-77 ft lb) Crankshaft Oil Baffle Nuts ......................................................................................... ...................................................................... 17-21 Nm (13-15 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Technical Service Bulletins > Block Heater - Replacement When Removing Motor Mounts Engine Block Heater: Technical Service Bulletins Block Heater - Replacement When Removing Motor Mounts Article No. 97-9-19 04/28/97 BLOCK HEATER - REMOVAL OF BLOCK HEATER WHEN REPLACING MOTOR MOUNTS LIGHT TRUCK: 1991-94 EXPLORER ISSUE: When installing a Vibration/Shake Kit per TSB 96-4-15, 96-4-16, or 96-4-17, the original block heater (if equipped) must be removed to allow installation of the revised engine mounts. The block heater cannot be reinstalled. ACTION: When performing any of the TSBs listed above, remove the previous block heater (if equipped) and install a revised design block heater into a new location on the block. Refer to Instruction Sheet 7222, included in the Block Heater Kit, for details. Install the Block Heater Kit only if the vehicle was originally equipped with a block heater. The Block Heater Kit (F67Z-6D008-EA) consists of the following: ^ One (1) Heater Element ^ One (1) Wiring Assembly ^ One (1) Instruction Sheet (1.5 7222) PART NUMBER PART NAME F67Z-6D008-EA Block Heater Kit OTHER APPLICABLE ARTICLES: 96-4-15, 96-4-16, 96-4-17 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 970919A Install Block Heater Kit 0.4 Hr. (this operation to be used when performing other listed TSBs at the same time) 970919B Install Block Heater Kit 0.8 Hr. (this operation to be used only if previous listed TSBs were performed during previous repair visit) DEALER CODING CONDITION BASIC PART NO. CODE 6K007 33 OASIS CODES: 205000, 499000, 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Height (above cyl block surface @ TDC) ............................................................................................................................................ 0.0015-00205 Standard Piston Diameter (measured at the piston pin bore centerline at 90° to the pin) .............................................................................. 3.9524-3.9531 Piston-To-Bore Clearance ..... .............................................................................................................................................................. ........... 0.0008-0.0019 Piston Pin Bore Diameter ................................................................................ .............................................................................................. 0.9450-0.9452 Compression Piston Ring Groove Width (Top) ............................................................................................................................................... 0.083-0.0811 Compression Piston Ring Groove Width (Bottom) ....................................................................................................................................... 0.1197-0.1205 Oil Piston Ring Groove Width ...................................................................................... ................................................................................. 0.1579-0.1587 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1571 Piston: Service and Repair Fig. 8 Piston & Rod Assembly Ensure arrow on piston dome faces front of engine as shown. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Length ................................................................................................................................ ............................................................... 2.835-2.886 Red Piston Pin Diameter ................................. ............................................................................................................................................... 0.9446-0.9448 Blue Piston Pin Diameter ............................................................................................ ................................................................................... 0.9448-0.9449 Pin-To-Piston Clearance ......... .............................................................................................................................................................. ...... 0.0003-0.OOO6 Pin-To-Rod Clearance ....................................................................................... ........................................................................................... Interference Fit Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Compression Piston Ring Width (Top) .......................................................................................................................................................... 0.0778-0.0783 Compression Piston Ring Width (Bottom) .................................................................................................................................................... 0.1172-0.1177 Compression Piston Ring Side Clearance (Top) ............................................................................................................................................ 0.0020-0.0033 Compression Piston Ring Side Clearance (Bottom) ...................................................................................................................................... 0.0020-0.0033 Piston Oil Ring Side Clearance ................................................................................... ............................................................................................. Snug Fit Side Clearance Service Limit .. .............................................................................................................................................................. ....................... 0.006 Compression Piston Ring Gap (Top) ................................................................. ................................................................................................ 0.015-0.023 Compression Piston Ring Gap (Bottom) ............................................................................................................................................................ 0.015-0.023 Piston Oil Ring Gap (Steel Rail) ...................................................................................... .................................................................................. 0.015-0.055 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1578 Piston Ring: Service and Repair Fig. 9 Piston Ring Gaps Pistons are available in standard sizes and oversizes. Ensure ring gaps are aligned as shown, Fig. 9. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations Valve Clearance: Locations Valve Arrangement (Front To Rear) ........................................................................................................................................................... L.H. I-E-I-E-I-E Valve Arrangement (Front To Rear) ........................................................................................................................................................... R.H. E-I-E-I-E-I Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations > Page 1583 Valve Clearance: Adjustments The hydraulic roller tappets have non-adjustable rocker arms. The tappets are not adjustable, and if found to be excessively worn or noisy, should be tested and replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Diameter ................................................................................................................. ......................................................... 0.7799-O.7811 Rocker Arm Bore Diameter ................................................................................................................. .......................................................... 0.7830-0.7842 Rocker Arm Ratio ................................................................................................................................ ....................................................................... 1.46:1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 1590 Rocker Arm Assembly: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect ignition wires from spark plugs. 2. Disconnect fuel lines. 3. On left valve cover, remove upper intake manifold if required. 4. On right valve cover, remove ignition coil and bracket assembly. 5. Remove PCV valve hose and breather. 6. Remove rocker arm attaching screws and load distributor washers. Ensure washers are installed in their original position. 7. Remove rocker arm covers. It may be necessary to lightly tap covers with a plastic hammer to break seal. Fig. 4 Rocker Arm Shaft Assembly 8. Loosen rocker arm shaft attaching bolts in sequence two turns at a time, then remove rocker arm and shaft assembly. 9. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Screws Are Tightened In Two Steps Step One ............................................................................................................................................. ...................................... 6-8 Nm (4.5-5.9 ft lb) Step Two ........................................................................................................................ Two Minutes Later Tighten Screws To Same Specification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side REMOVAL Intake Shield 1. Disconnect battery ground cable and remove intake shield and air intake tube. 2. Remove alternator and coil pack. 3. Remove retaining bolt from air conditioning pipe over upper intake manifold. 4. Remove ignition wires from clips on valve cover. 5. Using a suitable tool such as a door panel remover tool, remove two wiring harnesses from right valve cover. Vacuum Coupling 6. Disconnect vacuum hose at coupling over valve cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1596 Engine Wiring Harness 7. Remove engine wiring harness clip from valve cover-to-intake manifold stud. Do not pull on harness. Lift up on clip with your thumb. Valve Cover Reinforcement 8. Remove the valve cover bolts, reinforcement plates, and cover. INSTALLATION 1. Clean valve cover and cylinder head gasket surfaces. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1597 Valve Cover Gasket 2. Peel plastic film from valve cover gasket and stick in place on valve cover. Valve Cover Gasket Installation 3. Apply Silicone Rubber D6AZ-19562-BA (ESB-M4G92-A) or equivalent to the intake manifold-to-cylinder head parting seam and an 8 mm (1/8-inch) ball of sealer to valve cover bolt holes on exhaust side of cylinder head. NOTE: Since silicone rubber will set up within 15 minutes, if you are installing both covers. apply only to one side at a time. 4. Install the valve cover, bolts, and reinforcing plates and snug bolts starting from center and working in crisscross pattern to end bolts. Tighten in same pattern to 6-8 Nm (4.5-5.9 ft lb). Two minutes later tighten bolts to same specification. NOTE: Stud goes in upper rear hole. 5. Connect vacuum hose at coupling over the valve cover. 6. Install two wiring harness clips onto valve cover and clip to valve cover stud. 7. Install ignition wires into clips. 8. Install air conditioning and vacuum tube retaining bolt to upper manifold on either valve cover. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1598 9. Install coil pack, alternator, fan belt, air intake tube and air intake cover. 10. Connect battery ground cable, start engine and check for leaks. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1599 Valve Cover: Service and Repair Left Side REMOVAL Intake Shield 1. Disconnect battery ground cable and remove intake shield and air intake tube. 2. Remove bolt from air conditioning pipe over upper intake manifold. 3. Remove upper intake manifold. A/C Clutch Connector 3. Disconnect air conditioning compressor clutch connector and, using door trim panel remover tool, remove wiring harness from back of compressor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1600 A/C Compressor 4. Remove air conditioning compressor bolts, pull up tube that goes around back of engine and reposition compressor and tube out of the way. 5. Remove power brake vacuum hose and disconnect the other five hoses from vacuum tee on plenum. Tag hoses to aid installation. PCV Hoses 6. Remove PCV hose and valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1601 Engine Wiring Harness 7. Remove wiring harness from valve cover and position out of the way using door trim panel remover tool. 8. Remove spark plug wires from the spark plugs and clips on valve cover. Engine Wiring Harness 9. Remove engine wiring harness clip from valve cover-to-intake manifold stud. Do not pull on harness. Lift up on clip with your thumb. 10. Remove retaining bolt from fuel hose clip to front of engine to allow fuel hoses to be moved enough to gain access to upper front valve cover bolt. Valve Cover Reinforcement Plate Removal 11. Remove bolts, reinforcement plates, and the valve cover. INSTALLATION 1. Clean valve cover, cylinder head, and intake manifold gasket surfaces. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1602 Valve Cover Gasket 2. Peel plastic film from valve cover gasket and stick in place on valve cover. Valve Cover Gasket Installation 3. Apply Silicone Rubber D6AZ-19562-BA (ESB-M4G92-A) or equivalent to the intake manifold-to-cylinder head parting seam and an 8 mm (1/8-inch) ball of sealer to valve cover bolt holes on exhaust side of cylinder head. NOTE: Since silicone rubber will set up within 15 minutes, if you are installing both covers. apply only to one side at a time. 4. Install the valve cover, reinforcing plates, and bolts and snug bolts starting from center bolts and working in crisscross pattern to end bolts. Tighten in same pattern to 6-8 Nm (4.5-5.9 ft lb). Two minutes later tighten bolts to same specification. NOTE: Stud goes in upper rear hole. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 1603 Upper Intake Manifold 5. Install upper intake manifold tighten bolts to 20-25 Nm (15-18 ft lb). 6. Install fuel hose clip-to-front of engine retaining bolt. 7. Install the ignition wires on spark plugs and clips. 8. Install wiring harness clips onto valve cover and rear valve cover stud. 9. Install PCV valve and hose. 10. Put air conditioning compressor and tube that goes around back of engine back into place. 11. Install air conditioning compressor bolts and tighten to 24-30 Nm (18-23 ft-lb). 12. Connect five vacuum hoses on top on plenum and install power brake vacuum hose. 13. Install wiring harness and clip to back of air compressor and plug in air conditioning clutch connector. 14. Install air conditioning and vacuum tube retaining bolt to upper manifold on either valve cover. 15. Connect battery ground cable, start engine and check for leaks. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Valve Guide Bore Diameter ................................................................................................................. ....................................................... 0.3174.0-0.3184 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 1607 Valve Guide: Service and Repair Valve guides consist of holes bored in the cylinder head. For service the guides can be reamed oversize to accommodate valves with oversize stems of .016, 0.030 and 0.032 inch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Intake Valve Seat Width ...................................................................................................................... .............................................................. 0.060-0.079 Exhaust Valve Seat Width ................................ ................................................................................................................................................. 0.060-0.079 Valve Seat Angle ............................................................................................................. ................................................................................................ 45° Valve Seat Runout Limit (T.I.R. Max) ..................................................................................................................................................... .................. 0.0015 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs Compression Pressure (lb. @ Spec. Length) ........................................................................................................................... .......................................... 60.0-68.0 @ 1.585 (lb. @ Spec. Length) .................................................. .............................................................................................................. 138.0-149.O @ 1.222 Valve Spring Free Length (Approximate) ............................................................................................ .......................................................................... 1.91 Valve Spring Assembled Height ....................... .......................................................................................................................................... 1-37/64-1-39/64 Valve Spring Service Limit ........................................................................................................................................ 10% pressure loss @ specified length Valve Spring Out-Of-Square .......................................................... ................................................................................................................... 5/64 (0.078) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Intake Valve Stem-to-guide Clearance ........................................................................................................................................................... 0.0008-0.0025 Exhaust Valve Stem-to-guide Clearance ........................................................................................................................................................ 0.0018-0.0035 Service Clearance ....................................................................................................... ................................................................................................ 0.0055 Intake Valve Head Diameter ... ............................................................................................................................................................. 43.5 mm (1.71 Inch) Exhaust Valve Head Diameter .............................................................................................................................................................. 34.5 mm (1.36 Inch) Valve Face Runout Limit .................................................................................... ................................................................................................ 0.002 Max. Valve Face Angle ............. .............................................................................................................................................................. ................................. 44° Intake Valve Stem Diameter (std.) .............................................................. ................................................................................................... 0.3159-0.3167 Exhaust Valve Stem Diameter (std.) .............................................................................................................................................................. 0.3149-0.3156 Intake Valve Stem Diameter (0.008 oversize) ............................................................................................................................................... 0.3239-0.3245 Exhaust Valve Stem Diameter (0.008 oversize) ............................................................................................................................................ 0.3228-0.3235 Intake Valve Stem Diameter (0.016 oversize.) .............................................................................................................................................. 0.3318-0.3324 Exhaust Valve Stem Diameter (0.016 oversize.) ........................................................................................................................................... 0.33O7-0.3314 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Routing New Or Used Belt (Measured At "A") ............................................................................................................................... 480-586 Newtons (108-132 lbs) Allowable Minimum ....................................................................................................... .................................................................. 480 Newtons (108 lbs) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1621 Drive Belt Routing Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1622 Drive Belt: Adjustments No adjustments are necessary; automatic tensioner gauges when belt should be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 1623 Drive Belt: Service and Repair Fig. 11 Serpentine Drive Belt Routine REMOVAL AND INSTALLATION 1. Raise tensioner by turning counterclockwise, then remove belt. 2. Install new belt over pulleys, then raise tensioner and slide belt underneath. Release tensioner to rest pulley on belt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Adjustments Drive Belt Tensioner: Adjustments No adjustments are necessary; automatic tensioner gauges when belt should be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving Engine Mount: Customer Interest Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving > Page 1635 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving Engine Mount: Customer Interest Engine Mounts - Vibration/Shake While Driving Article No. 96-4-15 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) - WHEN DRIVING OVER A BUMP - 4-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 4-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1993-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs at all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be caused by the movement frequency of the engine aligning with the tire rotation frequency causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install new design LH and RH engine mounts and rear axle-to-frame lateral shock absorber kit. Refer to the Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate year Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR THE NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1640 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber kit (F67Z-6k007-AA) (Figures 1, 2, and 3). Refer to the Instruction Sheets included with the kit for service details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1641 4. Road test vehicle to verify the concern has been corrected. The Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) consists of the following: LH Engine Mount ^ One (1) Insulator Assembly (LH) ^ One (1) Engine Mounting Bracket ^ Four (4) M10x25 Bolts ^ One (1) Nut/Washer Assembly ^ One (1) M12x1.75 Hex Flange Head Nut RH Engine Mount ^ One (1) Insulator Assembly (RH) ^ One (1) Engine Mounting Bracket ^ Three (3) M10x25 Bolts ^ One (1) Nut/Washer Assembly ^ One (1) M12x1.75 Hex Flange Head Nut Rear Axle-to-Frame Lateral Shock Absorber ^ One (1) Axle Pinion Damper ^ Three (3) M10 Bolts ^ One (1) Shock Absorber ^ Two (2) M12 Bolts ^ Two (2) M12 Flag Nuts ^ One (1) Frame Bracket ^ Three (3) M10 Bolts ^ Three (3) M10 Nuts ^ One (1) Instruction Sheet (I.S. # 6611C) NOTE: FOR 1991-92, 4-DOOR, REFER TO TSB ARTICLE 96-4-16. FOR 1991-94, 2-DOOR, REFER TO TSB ARTICLE 96-4-17. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit OTHER APPLICABLE ARTICLES: 96-4-17, 96-4-16 SUPERSEDES: 95-21-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960415A Replace Engine Mount 2.9 Hrs. Assemblies And Install Rear Axle Lateral Shock Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Customer Interest for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1642 Absorber DEALER CODING CONDITION BASIC PART NO. CODE 6K007 33 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving Engine Mount: All Technical Service Bulletins Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving > Page 1648 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving Engine Mount: All Technical Service Bulletins Engine Mounts - Vibration/Shake While Driving Article No. 96-4-15 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) - WHEN DRIVING OVER A BUMP - 4-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 4-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1993-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs at all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be caused by the movement frequency of the engine aligning with the tire rotation frequency causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install new design LH and RH engine mounts and rear axle-to-frame lateral shock absorber kit. Refer to the Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate year Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR THE NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1653 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber kit (F67Z-6k007-AA) (Figures 1, 2, and 3). Refer to the Instruction Sheets included with the kit for service details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1654 4. Road test vehicle to verify the concern has been corrected. The Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) consists of the following: LH Engine Mount ^ One (1) Insulator Assembly (LH) ^ One (1) Engine Mounting Bracket ^ Four (4) M10x25 Bolts ^ One (1) Nut/Washer Assembly ^ One (1) M12x1.75 Hex Flange Head Nut RH Engine Mount ^ One (1) Insulator Assembly (RH) ^ One (1) Engine Mounting Bracket ^ Three (3) M10x25 Bolts ^ One (1) Nut/Washer Assembly ^ One (1) M12x1.75 Hex Flange Head Nut Rear Axle-to-Frame Lateral Shock Absorber ^ One (1) Axle Pinion Damper ^ Three (3) M10 Bolts ^ One (1) Shock Absorber ^ Two (2) M12 Bolts ^ Two (2) M12 Flag Nuts ^ One (1) Frame Bracket ^ Three (3) M10 Bolts ^ Three (3) M10 Nuts ^ One (1) Instruction Sheet (I.S. # 6611C) NOTE: FOR 1991-92, 4-DOOR, REFER TO TSB ARTICLE 96-4-16. FOR 1991-94, 2-DOOR, REFER TO TSB ARTICLE 96-4-17. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit OTHER APPLICABLE ARTICLES: 96-4-17, 96-4-16 SUPERSEDES: 95-21-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960415A Replace Engine Mount 2.9 Hrs. Assemblies And Install Rear Axle Lateral Shock Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Mount: > 96415 > Feb > 96 > Engine Mounts - Vibration/Shake While Driving > Page 1655 Absorber DEALER CODING CONDITION BASIC PART NO. CODE 6K007 33 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1656 Engine Mount: Service and Repair REMOVAL AND INSTALLATION 1. Remove fan shroud attaching screws, then support engine using a suitable jack and block of wood under oil pan. 2. Remove insulator to crossmember attaching nuts and washers, then raise engine until insulator stud clears crossmember. 3. Remove fuel pump shield to left side engine bracket attaching bolt, if necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 1657 Fig. 1 Engine Mounts 4. Remove mount to cylinder block attaching bolts and the mount, Fig. 1. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise Idler Pulley: Customer Interest Accessory Drive Belt - Squeal or Hoot Noise Article No. 96-14-9 07/01/96 ^ FRONT END ACCESSORY DRIVE (FEAD) "SQUEAL/HOOT" - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) ^ NOISE - "SQUEAL/HOOT" FROM FRONT END ACCESSORY DRIVE (FEAD) AREA - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) FORD: 1991-96 THUNDERBIRD 1994-96 MUSTANG LIGHT TRUCK: 1991-94 EXPLORER 1991-95 AEROSTAR 1997 F-150 ISSUE: Some vehicles may experience a "squeal/hoot" noise during cold start-up (usually after cold soak at temperatures of -18°C/0°F (or below) coming from the Front End Accessory Drive (FEAD) area. This may be caused by the tolerance of the grease being used within the idler pulley bearing in cold temperatures. ACTION: Confirm the noise is coming from the idler pulley (or the tensioner pulley bearing for the 4.0L Explorer) and replace the idler pulley which has a revised composition grease to reduce the possibility of noise in cold temperatures. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using a technician's stethoscope, check for noise at the idler pulley (4.0L Explorer, at the tensioner pulley bearing). WARNING: DO NOT RUN THE ENGINE FOR MORE THAN 30 SECONDS WITH THE FEAD BELT REMOVED. 2. Remove the FEAD belt and start the engine. With the engine running, check to see if the noise is still present. If the noise is not present, proceed to Step 3. If the noise is still present, this TSB is no longer applicable. 3. Replace the idler pulley with a revised idler pulley selected from the Application Chart. Refer to the appropriate model/year Service Manual for removal and installation procedures. NOTE: THE BOLT SECURING THE IDLER PULLEY TO THE TENSIONER ASSEMBLY IS A LH THREAD AND SHOULD BE TORQUED TO 40.7 N-m (30 LB-FT) MINIMUM. PART NUMBER PART NAME F5PZ-8678-AA Idler Pulley F6PZ-8678-AB Idler Pulley OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise > Page 1666 OPERATION DESCRIPTION TIME 961409A Replace Idler Pulley Or 0.3 Hr. Tensioner Pulley DEALER CODING CONDITION BASIC PART NO. CODE 8678 56 OASIS CODES: 497000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise Idler Pulley: All Technical Service Bulletins Accessory Drive Belt - Squeal or Hoot Noise Article No. 96-14-9 07/01/96 ^ FRONT END ACCESSORY DRIVE (FEAD) "SQUEAL/HOOT" - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) ^ NOISE - "SQUEAL/HOOT" FROM FRONT END ACCESSORY DRIVE (FEAD) AREA - DURING COLD START-UP AFTER COLD SOAK BELOW -18 DEGREES C (0 DEGREES F) FORD: 1991-96 THUNDERBIRD 1994-96 MUSTANG LIGHT TRUCK: 1991-94 EXPLORER 1991-95 AEROSTAR 1997 F-150 ISSUE: Some vehicles may experience a "squeal/hoot" noise during cold start-up (usually after cold soak at temperatures of -18°C/0°F (or below) coming from the Front End Accessory Drive (FEAD) area. This may be caused by the tolerance of the grease being used within the idler pulley bearing in cold temperatures. ACTION: Confirm the noise is coming from the idler pulley (or the tensioner pulley bearing for the 4.0L Explorer) and replace the idler pulley which has a revised composition grease to reduce the possibility of noise in cold temperatures. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using a technician's stethoscope, check for noise at the idler pulley (4.0L Explorer, at the tensioner pulley bearing). WARNING: DO NOT RUN THE ENGINE FOR MORE THAN 30 SECONDS WITH THE FEAD BELT REMOVED. 2. Remove the FEAD belt and start the engine. With the engine running, check to see if the noise is still present. If the noise is not present, proceed to Step 3. If the noise is still present, this TSB is no longer applicable. 3. Replace the idler pulley with a revised idler pulley selected from the Application Chart. Refer to the appropriate model/year Service Manual for removal and installation procedures. NOTE: THE BOLT SECURING THE IDLER PULLEY TO THE TENSIONER ASSEMBLY IS A LH THREAD AND SHOULD BE TORQUED TO 40.7 N-m (30 LB-FT) MINIMUM. PART NUMBER PART NAME F5PZ-8678-AA Idler Pulley F6PZ-8678-AB Idler Pulley OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: > 96149 > Jul > 96 > Accessory Drive Belt - Squeal or Hoot Noise > Page 1672 OPERATION DESCRIPTION TIME 961409A Replace Idler Pulley Or 0.3 Hr. Tensioner Pulley DEALER CODING CONDITION BASIC PART NO. CODE 8678 56 OASIS CODES: 497000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Refill (3.0L) .......................................................................................................................................... ........................................................... 3.5 Qts.(3.3L) Refill (2.3L, 4.0L) ................................................................................................................................. .......................................................... 4.0 Qts.(3.8L) Note: Capacity shown without filter. When replacing filter, additional oil may be needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1680 Engine Oil: Fluid Type Specifications Motorcraft Motor Oil 5W30 Super Premium ......................................................................................................................... ESE-M2C153-E and API SG Motorcraft Motor Oil 10W30 Super Premium ....................................................................................................................... ESE-M2C153-E and API SG Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Description and Operation > Page 1684 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Nuts And Bolts ........................................................................................................................ .................................................. 7-10 Nm (5-7 ft lb) Transmission To Oil Pan Bolts ......................................................................................................................................................... 38-51 Nm (28-38 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1691 Oil Pan: Service and Repair *** THIS ARTICLE REFLECTS CHANGES MADE BY TSB 9518 DATED JANUARY 16, 1995 REMOVAL 1. Remove the engine. 2. Mount the engine on an engine stand with the engine upright. Remove the oil pan and crankshaft oil windage baffle. CAUTION: Mounting the engine upside down on the engine stand before removing the oil pan may cause sludge to drop into the cylinders and onto the camshaft and valve tappets causing rapid wear when the engine is restarted. 3. Rotate the engine upside down and remove the oil pump and rear main bearing cap and wedge seal. 4. Remove and discard the crankshaft rear main seal. INSTALLATION CAUTION: Prevent engine assembly contamination. Always use necessary precautions to prevent old sealer or gasket material from falling into the engine. 1. Thoroughly clean all the oil and the old sealer from the oil pan taking special care to remove all the old sealer from the oil pan gasket groove in the oil pan. Thoroughly clean the oil pan. 2. Thoroughly clean all the old sealer from the rear main bearing cap using a scraper and wire wheel. The original sealer used during production assembly becomes extremely hard after it has cured. It is extremely important that all old sealer is removed from all joining faces and grooves. 3. Thoroughly clean all oil and old sealer from the cylinder block oil pan sealing area and the rear main bearing cap joint area. 4. Thoroughly clean all oil and old sealer from the wedge seal sealing area at the rear main bearing cap and the oil pan gasket groove. NOTE: Preferably use a new wedge seal. 5. After all parts have been thoroughly cleaned and washed, it is necessary and extremely important that they be wiped down with Extra Strength Spot and Stain Remover B7A-19521-AA (ESR-M5B197-A) or denatured alcohol. 6. Thoroughly clean the transmission bell-housing area and the rear of the cylinder block. Oil removal should be verified with an ultraviolet lamp ("black light"). Cylinder Block Sealer Application 7. Place a bead of Ford Gasket Eliminator E1FZ-19562-A (ESE-M4G234-A1), Loctite 515 or equivalent sealer to the cylinder block along the corners of the rear main bearing cap joint area, and on the joint face approximately 13 mm (1/2 inch) from the rear of the cylinder block. 8. Verify that the lower rear main bearing insert is in place and install the rear main bearing cap and snug the bolts. NOTE: New main bearing cap bolts must be used during assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1692 Rear Main Bearing Cap View 9. Align the rear main bearing cap to block by moving the bearing cap fore or aft so the rear seal stop (located approximately 1/2 inch inward in the rear oil seal bore) of the block and cap line up. This will assure the crankshaft rear oil seal will seat properly when installed in the bore. NOTE: The rear main bearing cap must be aligned and installed properly to seal. Misalignment will cause an oil leak. 10. Tighten the bolts evenly to 90-104 Nm (66-77 ft lb). Wedge Seal Sealer Application 11. Fill the cavities for the wedge seal on both sides of the rear main cap and the small groove in the oil pan gasket area of the rear main cap with Ford Gasket Eliminator E1FZ-19562-A (ESE-M4G234-A1), Loctite 515 or equivalent sealer. CAUTION: Use a new oil seal. Failure to install a new seal, or incorrect installation will result in an oil leak after the vehicle is returned to service. 12. Place wedge seal in position and use a flat blade screwdriver or equivalent to fully seat the wedge seal, forcing the excess sealer out around the seal. Wipe the excessive sealer from the cylinder block and rear main cap area. 13. Clean and inspect the oil inlet tube. Prime the oil pump by filling the inlet opening with oil while rotating the shaft until oil emerges from the outlet opening. Install the pump and screen and tighten the bolts to 17-21 Nm (13-15 ft lb). 14. Install the windage tray and tighten to 17-21 Nm (13-15 ft lb). 15. Place a bead of Ford Silicone Sealer F1AZ-19562-A. Loctite 598 or equivalent sealer in the oil pan gasket groove at the radius areas at the front Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1693 and rear of the oil pan. 16. Place the oil pan gasket into the groove in the oil pan. 17. Place a bead of Ford Silicone Sealer F1AZ- 19562-A, Loctite 598 or equivalent sealer on top of the oil pan gasket at the radius areas at the front and rear of the oil pan. 18. Place a bead of Ford Silicone Sealer F1AZ-19562-A, Loctite 598 sealer, or equivalent on the cylinder block at the cylinder block-to-front cover joint area. Oil Pan Installation 19. Set the oil pan in place. Install and snug four oil pan nuts tight enough to align the bolt holes, but loose enough that the oil pan may be pushed backwards. 20. Align the rear face of the oil pan with the rear face of the cylinder block. NOTE: If the rear face of the oil pan cannot be aligned within 0.010 inch of the rear face of the cylinder block, the oil pan spacer should be used. 21. Install the remaining oil pan bolts and finger-tighten. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1694 22. Tighten the oil pan nuts and bolts evenly to 7-10 Nm (5-7 ft lb). NOTE: Do not put oil in the engine or run the engine until the next day to allow the sealers to set up properly. If time is not allowed for sealers to cure, engine will leak. 23. Always use a new crankshaft rear oil seal. CAUTION: This installation procedure requires the use of hand tools only. The use of power tools or hammering on the installer can damage the sleeve and seal. Rear Main Seal Installation Tool a. Attach the rear crankshaft adapter to the rear of the crankshaft using the supplied mounting screws. Rear Main Oil Seal Installation b. Apply a few drops of clean engine oil to the inboard side of the seal/sleeve at the area where the seal contacts the sleeve. c. Apply a very light film of clean engine oil on the inner diameter of the sleeve and outer diameter of seal. d. Slide the seal/sleeve over the rear crankshaft seal adapter with flange to the rear of the engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1695 e. Use the rear crankshaft seal replacer and supplied bolt to push the rear seal into the cylinder block. NOTE: It is normal for the seal to sit approximately 0.76 mm (0.030 inch) deeper than the sleeve flange. Do not adjust. f. Remove the rear crankshaft seal adapter. 24. Determine if oil pan spacers will be required at installation. CAUTION: Failure to measure the required spacer thickness will result in insufficient or excessive clearances between the oil pan and the transmission when installed in the vehicle. This can result in oil pan damage and an oil leak. NOTE: The transmission bolts to the engine and oil pan when installed, so it is important to measure the gap between the surface of the rear face of the oil pan (at the spacer locations) and the rear face of the cylinder block. Refer to the following procedure for checking this dimension. Rear View Of Engine a. With the oil pan installed on the engine, position straightedge D83L-4201-A or equivalent flat on the rear of the cylinder block so that it extends over one of the oil pan/transmission bolt mounting pads. Spacer Selection Chart b. Using Feeler Gauge D81L-4201-A or equivalent, measure the gap between the mounting pad and the straight edge. Repeat the procedure for the other mounting pad. Select oil pan spacer of the required thickness from the chart. c. Install the selected oil pan spacer to the mounting pads on the rear of the oil pan before bolting the engine and transmission together. 25. Install flywheel. Tighten flywheel bolts in two stages. a. First stage - 12-15 Nm (9-11 ft lb) b. Second stage - 68-74 Nm (50-55 ft lb) 26. Remove engine from stand and install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Oil Pressure Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Oil Pressure Gauge Inaccurate Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 1701 Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 1702 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations Oil Pressure Switch: Component Locations All Except Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 1707 Limited Edition And Electronic Group Left Hand Side Of Engine, Next To Power Steering Pump Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 1708 Oil Pressure Switch: Connector Locations Left Hand Side Of Engine, Next To Power Steering Pump Oil Pressure Sending Unit Connector # C175 .............................................................................................................................................................. ....... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > General Specifications Oil Pump: Specifications General Specifications Oil Pump Relief Valve Spring Tension (Lbs. @ Spec. Length) ........................................................................................................................ ............................................ 13.6-14.7 @ 1.39 Oil Pump Drive Shaft-To-Housing Bearing Clearance .................................................................................................................................. 0.0015-0.0030 Oil Pump Relief Valve-To-Bore Clearance ................................................................................................................................................... 0.0015-0.0030 Oil Pump Rotor Assembly End Clearance (Assembled) ..................................................................................................................................... 0.004 Max. Oil Pump Outer Race-To-Housing Clearance .................................................................................................................................................... 0.001-0.013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > General Specifications > Page 1716 Oil Pump: Specifications Torque Oil Pump Drive Assembly Hold Down Bolts ................................................................................................................................... 17-21 Nm (13-15 ft lb) Oil Pump Pick-Up To Pump Screws .................................................................................................................................................... 9-13 Nm (7-10 ft lb) Oil Pump To engine Block Screws ................................................................................................................................................... 17-21 Nm (13-15 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1717 Oil Pump: Service and Repair *** THIS ARTICLE REFLECTS CHANGES MADE BY TSB 9518 DATED JANUARY 16, 1995 REMOVAL 1. Remove the engine assembly from the vehicle. 2. Mount the engine on a suitable engine stand with the oil pan facing up. 3. Remove the oil pan retaining bolts and remove the oil pan. 4. Remove the oil pan gasket, oil pump, oil baffle, rear main bearing cap and wedge seal. 5. Remove and discard the crankshaft rear main seal. 6. Thoroughly clean the gasket mating surfaces of the engine block, oil pan and the rear main bearing cap. 7. Clean the oil seal recess in the cylinder block and main bearing cap. Inspect and clean the oil seal contact surface on the crankshaft. INSTALLATION Oil Pan Installation View NOTE: Ford Gasket Eliminator, E1FZ-19562-A is equivalent to Loctite(R) 515. Ford Silicone Sealer, F1AZ-19562-A is equivalent to Loctite(R) 598. 1. Clean the gasket surfaces of the oil pan. Thoroughly clean all oil and all residual old sealer from the oil pan. Remove all the old sealer from the oil pan gasket groove in the oil pan sealing surface. Thoroughly wash the oil pan. 2. Thoroughly clean all the old sealer from the rear main bearing cap using a scraper and wire wheel. The original sealer used during production assembly becomes extremely hard after it has cured. It is extremely important that all old sealer is removed from all joining faces and grooves. 3. Thoroughly clean all oil and old sealer from the cylinder block oil pan sealing area and the rear main bearing cap joint area. 4. Thoroughly clean all oil and old sealer from the wedge seal sealing area at the rear main bearing cap and the oil pan gasket groove. 5. After all parts have been thoroughly cleaned and washed, it is necessary and extremely important that they be wiped down with Extra Strength Spot and Stain Remover B7A-19521-AA (ESR-M5B197-A) or Denatured Alcohol. 6. Thoroughly clean the transmission bell-housing area and the rear of the cylinder block. Oil removal should be verified with an ultraviolet lamp ("black light"). 7. Place a bead of Loctite(R) 515 sealer along the block corners of the rear main bearing cap joint area, and on the joint face approximately 1/2 inch from the rear of the block. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1718 Rear Main Bearing Cap View 8. Coat the main bearing insert and crankshaft journal with SAE 50 Service SG (ESE-M2C39-F) oil, apply Loctite(R) 515 sealer to the rear main bearing cap as shown in the illustration. Verify the main bearing insert is properly installed. 9. Align the rear main bearing cap to block by moving the bearing cap fore or aft so the rear seal stop (located approximately 1/2 inch inward in the rear oil seal bore) of the block and cap line up. This will assure the rear main oil seal will seat properly when installed in the bore. NOTE: The rear main bearing cap MUST be aligned and installed properly to seal. Misalignment will cause an oil leak. 10. New rear main bearing cap bolts must be used. Tighten the bolts evenly to 90-104 Nm (66-77 ft lb). CAUTION:Use a new oil seal. Failure to install a new seal, or incorrect seal installation will result in an oil leak after the vehicle is returned to service. 11. Use a new wedge seal. Fill the cavities for the wedge seal on both sides of the rear main cap and the small groove in the oil pan gasket area of the rear main cap with Loctite(R) 515 sealer. 12. Place wedge seal in position and use a flat blade screwdriver or equivalent to fully seat the wedge seal, forcing the excess sealer out around the seal. Do not remove the excess sealant. 13. Clean and inspect the oil inlet tube. Prime the oil pump by filling the inlet opening with oil while rotating the shaft until oil emerges from the outlet opening. Install the pump and screen and tighten the screws to 17-21 Nm (13-15 ft lb). 14. Install the oil baffle assembly and tighten the nuts to 17-21 Nm (13-15 ft lb). 15. Determine if shim spacers will be required at installation. NOTE: The transmission bolts to the engine and oil pan when installed, so it is important to measure the gap between the surface of the rear face of the oil pan (at the spacer locations) and the rear face of the engine block. Refer to the steps a,b,c, and d below for checking this dimension. CAUTION:Failure to measure the required spacer thickness will result in insufficient or excessive clearance between the engine oil pan and the transmission when installed in the vehicle. This can result in oil pan damage and/or an oil leak. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1719 Rear View Of Engine a. With the oil pan installed on the engine, position straightedge D83L-4201-A or equivalent flat on the rear of the engine block (as shown) so that it extends over one of the oil pan/transmission bolt mounting pads. Oil Pan To Transmission Spacer Usage Chart b. Using feeler gauge D81L-4201-A or equivalent, measure the gap between the mounting pad and the straight edge. Repeat the procedure for the other mounting pad. Select spacers of the required thickness from the chart. c. Install the selected spacers to the mounting pads on the rear of the oil pan before bolting the engine and transmission together. d. Remove the oil pan and position the correct spacers for pan installation. 16. Place a bead of Loctite(R) 598 sealer in the oil pan gasket groove at the radius areas at the front and rear of the oil pan. 17. Place the oil pan gasket into the groove in the oil pan. 18. Place a bead of Loctite(R) 598 sealer on top of the oil pan gasket at the radius areas at the front and rear of the oil pan. 19. Set the oil pan in place and finger-tighten the oil pan nuts on the studs enough to align the bolt holes, but loose enough to allow the pan to move. 20. Align the rear face of the oil pan with the rear face of the cylinder block. NOTE: If the rear face of the oil pan cannot be aligned within .010 inch of the rear face of the cylinder block, the appropriate shims should be used. 21. Install the remaining oil pan bolts and finger-tighten. 22. Tighten the oil pan nuts and bolts evenly to 7-10 Nm (62-88 in lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications > Page 1720 Rear Main Seal Installation Tool 23. Always use a new rear oil seal. Coat the rear main seal-to-cylinder block surface of the oil seal with oil X0-5W30-QSP (WSE-M2903-A1) or equivalent SAE 5W-30 Service SG oil. Coat the seal contact surface of the oil seal and crankshaft with heavy SF engine oil. Install the new seal using Rear Oil Seal Installer T95T-6701-A. 24. Remove the engine from the stand and reinstall in the vehicle. NOTE: It is recommended that the engine not be run or oil be added for 24 hours to allow sealers to cure properly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss Intake Manifold: Customer Interest Cooling System - Coolant Loss Article No. 95-9-10 05/08/95 ^ COOLING SYSTEM - LOSS OF COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE ^ LEAKS - COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER, RANGER ISSUE: Coolant loss, with no visible sign of leakage, may occur on some vehicles. This may be due to internal leaks from a failed intake manifold gasket caused by loose intake manifold bolts, a fouled intake manifold, pitting/corrosion, or loose cylinder head bolts. ACTION: Refer to the following procedures for service details. NOTE: DUE TO AIR BEING TRAPPED IN THE COOLING SYSTEM, IT IS NOT UNUSUAL TO ADD 44 OZ (118-207 ML) COOLANT UP TO 7500 MILES (12,000 KM) AFTER INITIAL FILL. INSPECTION PROCEDURE 1. Run the engine for 10 minutes, or as required, to build pressure in the cooling system for a leak inspection. Examine the radiator, side tanks, coolant recovery bottle, hoses and connections, intake manifold, cylinder heads and block for external coolant leaks. If no external leak can be found, then the concern may be with the lower intake manifold gasket, intake manifold pitting/corrosion, or with low cylinder head bolt torque. 2. Measure the cylinder head bolt torque. If torque is less than 80 N-m (59 lb.ft.), replace Cylinder Head Gasket (F5TZ-6051-A RH, and F5TZ-6051-B LH) using the procedure in this TSB article. 3. If coolant loss continues, even with proper head bolt torque, remove intake manifold and remove all old gasket material and any coolant residue with a soft non-metallic or aluminum wire brush. Inspect manifold for corrosion/erosion/pitting damage at the four (4) water passages (Figure 1). If damaged, the intake manifold must be replaced. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1729 MANIFOLD MUST BE REPLACED. 4. Replace the lower intake manifold gasket with the new Carrier-type Intake Manifold Gasket (F5TZ-9439-A). Use the procedures found in this TSB article. DISASSEMBLY PROCEDURE - INTAKE AND CYLINDER HEAD GASKETS Service the intake manifold (lower) and cylinder head gaskets per the appropriate Powertrain/Drivetrain Service Manual, when required. INSTALLATION ASSEMBLY PROCEDURE AFTER REMOVING BOTH CYLINDER HEAD AND INTAKE MANIFOLD 1. Remove all old gasket material with a soft non-metallic or aluminum wire brush. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. 2. Before installing the new gasket, remove all old sealer from the intake, heads and block surfaces, and check for proper condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. NOTE: THE 4.0L ENGINE SHOULD ALWAYS BE ASSEMBLED USING NEW CYLINDER HEAD BOLTS. 3. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Position the cylinder heads onto the head gaskets and locating dowels (Figure 4). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1730 NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (AS IN ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (E805676-S72). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W7OOl 66-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECEIVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE CYLINDER HEAD(S) AND INTAKE MANIFOLD ARE TORQUED ALTERNATELY AND IN SEQUENCE TO ENSURE CORRECT FIT AND GASKET CRUSH. FAILURE TO FOLLOW COMPLETE TORQUE SEQUENCE WILL CAUSE FOLLOW-UP REPAIR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1731 4. Install and torque cylinder head bolts, in the sequence shown. to 30 N-m (22 lb.ft) (Figure 5). NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 5. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). 6. Position the gasket with the help of the two (2) temporary guide studs (Item 3 Figure 6) located in Positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the tour (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1732 7. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Torque the intake manifold bolts, in sequence, to 4 N-m (3 lb.ft.) (Figure 7). Replace the two (2) studs with bolts (save the studs for use when necessary on future jobs). NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 8. Torque the cylinder head bolts, in sequence, to 70 N-m (52 lb.ft.) (Figure 5). 9. Torque the intake manifold bolts, in sequence, to 8 N-m (6 lb.ft.) (Figure 7). 10. For the final cylinder head torque step, rotate the cylinder head bolts 90 degrees in sequence (Figure 5). 11. If using bolts with a captive washer (1995 manifold), finish tightening the intake manifold, in sequence, to 15 N-m (11 lb.ft.). If using bolts without a captive washer (1990-94 manifold), tighten an additional step to 21 N-m (15 lb.ft.). 12. Install the valve push rods. Install the rocker arms as outlined in the Service Manual. 13. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. INSTALLATION PROCEDURE AFTER REMOVING ONLY THE INTAKE MANIFOLD 1. Before installing the new gaskets, remove all old sealer from the intake, heads and block surfaces, and check for proper surface condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE MANIFOLD MUST BE REPLACED. NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (W701104-S309). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W700166-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECIEVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 2. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1733 3. Position the gasket with the help of the two (2) temporary guide studs (Item 3, Figure 6) located in positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the four (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. 4. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Tighten the intake manifold in stages using the following torques and the sequence shown in Figure 7. a. 4 N-m (3 lb.ft.) NOTE: REPLACE THE TWO (2) STUDS WITH BOLTS (SAVE THE STUDS FOR USE WHEN NECESSARY ON FUTURE JOBS). b. 8 N-m (6 lb.ft.) c. 15 N-m (11 lb.ft.) NOTE: STOP HERE IF THE INTAKE MANIFOLD BEING INSTALLED IS A 1995 (BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A OR WIDE AREA FOR THE BOLT HOLE SPOTFACE). THE FOLLOWING STEP APPLIES ONLY TO PRIOR YEAR MANIFOLDS. d. 21 N-m (15 lb.ft.) NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 5. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. VALVE COVER AND GASKET INSTALLATION PROCEDURE 1. Clean valve cover, intake manifold, cylinder head gasket surfaces and threaded bolt holes. NOTE: SINCE SILICONE RUBBER SEALANT WILL SET-UP IN 15 MINUTES, APPLY TO ONE (1) VALVE COVER AT A TIME, IF YOU ARE INSTALLING BOTH COVERS. 2. Apply a small amount (peanut size) of Silicone Rubber Sealant, Loctite 598 (F1AZ-19562-A), or equivalent, to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1734 ^ The four (4) manifold locations at the joint where the intake manifold and the cylinder heads meet (Figure 3, Position A). ^ Any casting irregularity on the gasket sealing area of the cylinder head(s). NOTE: IF 1992 VEHICLES HAVE VALVE COVER GASKETS OF THE CORK TYPE, THESE GASKETS MUST BE REPLACED WITH METAL-TYPE (CARRIER) GASKET. THE NEW TYPE GASKET IS A THINNER GASKET, THEREFORE TO PREVENT BOTTOMING IT IS IMPORTANT TO RE-USE THE CONICAL SPRING WASHER SCREWS (W700099-S309M), M6X20 MM, TOGETHER WITH REINFORCEMENTS (FLANGE PLATES), -6A523-; AND STUD (E804194-S72), M6X20/M6X20, W10 WASHER, AND WITH REINFORCEMENT, -6A523-. SEE FIGURE 3. ALSO, SEE TSB 92-14-13. CAUTION: CHECK FOR BOTTOMING TO ENSURE CORRECT PARTS WERE INSTALLED DURING PREVIOUS REPAIR. ANY FAILURE TO USE CORRECT FASTENERS CAN RESULT IN AN OIL LEAK AND A REPEAT REPAIR. ALSO CHECK FOR VISIBLE FLATNESS OF THE VALVE COVER RAIL USING A STRAIGHT EDGE. AN OUT OF FLAT RAIL WILL REQUIRE A VALVE COVER REPLACEMENT, OR REPAIR. NOTE: LATER MODEL YEAR VEHICLES (LATE 1992 AND 1993 THROUGH CURRENT), SHOULD HAVE CARRIER GASKETS ALREADY INSTALLED, WITH SHORT SCREWS (W701035-S300), M6XM16MM, WITH CONICAL SPRING WASHERS; AND STUDS (W701041-S300), M6X16/M6X16MM WITH CONICAL SPRING WASHERS; AND SHOULD NOT HAVE REINFORCEMENTS. CHECK THAT THIS HARDWARE WAS INSTALLED AND THEN RE-USE FASTENERS. NOTE: STUD GOES IN UPPER REAR HOLE. ENSURE BOLT HOLES ARE CLEAN AND FREE OF OIL RESIDUE. 3. Install valve cover, rocker arm cover flange plates and bolts. Tighten bolts starting from center bolts and working in crisscross pattern to end bolts. Torque in the same pattern to 6-8 N-m (53-71 lb.in.). See Figure 3. Also, see TSB 92-14-13. 4. Continue reassembly per procedures in appropriate year Service Manual. 5. Fill cooling system using the "Filling and Bleeding the Coolant System" procedure in this TSB article. FILLING AND BLEEDING THE COOLANT SYSTEM WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR CAUSE PERSONAL INJURY. USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. IF POSSIBLE, WAIT UNTIL ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL USING A CLOTH), TURN AND REMOVE IT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1735 In order to bleed the cooling system properly after an initial fill with coolant, it might need up to five (5) cycles of the following: 1. Heating up the system (thermostat open). 2. Ensuring coolant is at least up to the "cold" fill mark of the overflow bottle. 3. Letting coolant cool down (temperature gauge below "N" of normal). 4. Topping off coolant overflow to "cold" mark. 5. Repeating cycle. FILLING WARNING: USE CAUTION WHEN ADDING COOLANT MIXTURE TO RADIATOR TO AVOID HOT COOLANT OR STEAM BLOW OUT FROM THE RADIATOR. NOTE: USE THE FOLLOWING STEPS TO REMOVE AIR FROM THE COOLING SYSTEM AND TO ENSURE A COMPLETE FILL CAN BE ACCOMPLISHED. NOTE: WHEN FILLING A CROSSFLOW RADIATOR, ALLOW TIME FOR THE COOLANT TO FLOW THROUGH THE RADIATOR TUBES TO THE OTHER END TANK TO ENSURE RADIATOR IS FULL. 1. Close radiator draincock and install cylinder block drain plug. 2. Fill the cooling system with a 50/50 ethylene glycol and water mixture. Allow several and then backing off to first stop. This will allow any air to escape and minimize spillage. 4. Slide heater temperature and mode selection levers to maximum heat position. 5. Start engine and allow to operate at fast idle (approximately 2000 rpm) for 3 to 4 minutes. Shut engine off. 6. With engine off, wrap radiator cap with a thick cloth, carefully remove radiator cap and add coolant to bring coolant level up to filler neck seat. 7. Replace radiator cap to fully-installed position. Then, back off to first stop. Operate engine at fast idle until the upper radiator hose is warm (water thermostat opens). To check radiator, shut engine off, wrap radiator cap with thick cloth and carefully remove radiator cap. Add additional coolant if necessary. Replace radiator cap to fully-installed position. 8. Open the small cap on the top of the radiator coolant recovery reservoir. The large cap is for the windshield washer reservoir. NEVER put coolant mixture in windshield washer bottle. 9. Using a suitable suction gun, remove all coolant from radiator coolant recovery reservoir. 10. Add 1 liter (1.1 quart) of 50/50 mixture of ethylene glycol and water to the radiator coolant recovery reservoir. Close small cap. NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON PREVIOUS MODEL YEAR INTAKE MANIFOLDS. USE BOLTS W700166-S309 WITH 1992-94 MANIFOLDS, AND USE BOLTS W702301-S309M WITH 1995 MANIFOLDS. 1995 MANIFOLDS MAY BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A. (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1736 Parts Block OTHER APPLICABLE ARTICLES: 92-14-13, 94-12-13, 94-14-13, 94-18-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950910A Replace Lower Intake 3.9 Hrs. Manifold Gasket - Aerostar (Not To Be Used With Operations D, E, Or F) 950910B Replace Lower Intake 2.7 Hrs. Manifold Gasket - Ranger, Explorer (Not To Be Used With Operations G, H, Or I) 9509100 Additional Time To 0.2 Hr. Replace Lower Intake Manifold - All Vehicles 950910D Replace Right Side 5.6 Hrs. Cylinder Head Gasket - Aerostar (Not To Be Used With Operation A) 950910E Replace Left Side Cylinder 5.4 Hrs. Head Gasket - Aerostar (Not To Be Used With Operation A) 950910F Replace Both Cylinder 7.5 Hrs. Head Gaskets - Aerostar (Not To Be Used With Operation A) 95O91OG Replace Right Side 3.8 Hrs. Cylinder Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910H Replace Left Side Cylinder 3.5 Hrs. Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910I Replace Both Cylinder 5.0 Hrs. Head Gaskets - Ranger, Explorer (Not To Be Used With Operation B) 95O91OJ Additional Time If 0.1 Hr. Equipped With Speed Control - All Vehicles (May Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1737 Only Be Used With Operations A Or B) 950910K Additional Time If 0.3 Hr. Equipped With A/C - Aerostar (Not To Be Used With Operation A) 95O910L Additional Time If 0.8 Hr. Equipped With A/C - Ranger, Explorer (Not To Be Used With Operation B) DEALER CODING CONDITION BASIC PART NO. CODE 6049 57 OASIS CODES: 402000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss Intake Manifold: All Technical Service Bulletins Cooling System - Coolant Loss Article No. 95-9-10 05/08/95 ^ COOLING SYSTEM - LOSS OF COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE ^ LEAKS - COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER, RANGER ISSUE: Coolant loss, with no visible sign of leakage, may occur on some vehicles. This may be due to internal leaks from a failed intake manifold gasket caused by loose intake manifold bolts, a fouled intake manifold, pitting/corrosion, or loose cylinder head bolts. ACTION: Refer to the following procedures for service details. NOTE: DUE TO AIR BEING TRAPPED IN THE COOLING SYSTEM, IT IS NOT UNUSUAL TO ADD 44 OZ (118-207 ML) COOLANT UP TO 7500 MILES (12,000 KM) AFTER INITIAL FILL. INSPECTION PROCEDURE 1. Run the engine for 10 minutes, or as required, to build pressure in the cooling system for a leak inspection. Examine the radiator, side tanks, coolant recovery bottle, hoses and connections, intake manifold, cylinder heads and block for external coolant leaks. If no external leak can be found, then the concern may be with the lower intake manifold gasket, intake manifold pitting/corrosion, or with low cylinder head bolt torque. 2. Measure the cylinder head bolt torque. If torque is less than 80 N-m (59 lb.ft.), replace Cylinder Head Gasket (F5TZ-6051-A RH, and F5TZ-6051-B LH) using the procedure in this TSB article. 3. If coolant loss continues, even with proper head bolt torque, remove intake manifold and remove all old gasket material and any coolant residue with a soft non-metallic or aluminum wire brush. Inspect manifold for corrosion/erosion/pitting damage at the four (4) water passages (Figure 1). If damaged, the intake manifold must be replaced. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1743 MANIFOLD MUST BE REPLACED. 4. Replace the lower intake manifold gasket with the new Carrier-type Intake Manifold Gasket (F5TZ-9439-A). Use the procedures found in this TSB article. DISASSEMBLY PROCEDURE - INTAKE AND CYLINDER HEAD GASKETS Service the intake manifold (lower) and cylinder head gaskets per the appropriate Powertrain/Drivetrain Service Manual, when required. INSTALLATION ASSEMBLY PROCEDURE AFTER REMOVING BOTH CYLINDER HEAD AND INTAKE MANIFOLD 1. Remove all old gasket material with a soft non-metallic or aluminum wire brush. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. 2. Before installing the new gasket, remove all old sealer from the intake, heads and block surfaces, and check for proper condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. NOTE: THE 4.0L ENGINE SHOULD ALWAYS BE ASSEMBLED USING NEW CYLINDER HEAD BOLTS. 3. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Position the cylinder heads onto the head gaskets and locating dowels (Figure 4). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1744 NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (AS IN ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (E805676-S72). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W7OOl 66-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECEIVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE CYLINDER HEAD(S) AND INTAKE MANIFOLD ARE TORQUED ALTERNATELY AND IN SEQUENCE TO ENSURE CORRECT FIT AND GASKET CRUSH. FAILURE TO FOLLOW COMPLETE TORQUE SEQUENCE WILL CAUSE FOLLOW-UP REPAIR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1745 4. Install and torque cylinder head bolts, in the sequence shown. to 30 N-m (22 lb.ft) (Figure 5). NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 5. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). 6. Position the gasket with the help of the two (2) temporary guide studs (Item 3 Figure 6) located in Positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the tour (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1746 7. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Torque the intake manifold bolts, in sequence, to 4 N-m (3 lb.ft.) (Figure 7). Replace the two (2) studs with bolts (save the studs for use when necessary on future jobs). NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 8. Torque the cylinder head bolts, in sequence, to 70 N-m (52 lb.ft.) (Figure 5). 9. Torque the intake manifold bolts, in sequence, to 8 N-m (6 lb.ft.) (Figure 7). 10. For the final cylinder head torque step, rotate the cylinder head bolts 90 degrees in sequence (Figure 5). 11. If using bolts with a captive washer (1995 manifold), finish tightening the intake manifold, in sequence, to 15 N-m (11 lb.ft.). If using bolts without a captive washer (1990-94 manifold), tighten an additional step to 21 N-m (15 lb.ft.). 12. Install the valve push rods. Install the rocker arms as outlined in the Service Manual. 13. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. INSTALLATION PROCEDURE AFTER REMOVING ONLY THE INTAKE MANIFOLD 1. Before installing the new gaskets, remove all old sealer from the intake, heads and block surfaces, and check for proper surface condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE MANIFOLD MUST BE REPLACED. NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (W701104-S309). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W700166-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECIEVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 2. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1747 3. Position the gasket with the help of the two (2) temporary guide studs (Item 3, Figure 6) located in positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the four (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. 4. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Tighten the intake manifold in stages using the following torques and the sequence shown in Figure 7. a. 4 N-m (3 lb.ft.) NOTE: REPLACE THE TWO (2) STUDS WITH BOLTS (SAVE THE STUDS FOR USE WHEN NECESSARY ON FUTURE JOBS). b. 8 N-m (6 lb.ft.) c. 15 N-m (11 lb.ft.) NOTE: STOP HERE IF THE INTAKE MANIFOLD BEING INSTALLED IS A 1995 (BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A OR WIDE AREA FOR THE BOLT HOLE SPOTFACE). THE FOLLOWING STEP APPLIES ONLY TO PRIOR YEAR MANIFOLDS. d. 21 N-m (15 lb.ft.) NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 5. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. VALVE COVER AND GASKET INSTALLATION PROCEDURE 1. Clean valve cover, intake manifold, cylinder head gasket surfaces and threaded bolt holes. NOTE: SINCE SILICONE RUBBER SEALANT WILL SET-UP IN 15 MINUTES, APPLY TO ONE (1) VALVE COVER AT A TIME, IF YOU ARE INSTALLING BOTH COVERS. 2. Apply a small amount (peanut size) of Silicone Rubber Sealant, Loctite 598 (F1AZ-19562-A), or equivalent, to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1748 ^ The four (4) manifold locations at the joint where the intake manifold and the cylinder heads meet (Figure 3, Position A). ^ Any casting irregularity on the gasket sealing area of the cylinder head(s). NOTE: IF 1992 VEHICLES HAVE VALVE COVER GASKETS OF THE CORK TYPE, THESE GASKETS MUST BE REPLACED WITH METAL-TYPE (CARRIER) GASKET. THE NEW TYPE GASKET IS A THINNER GASKET, THEREFORE TO PREVENT BOTTOMING IT IS IMPORTANT TO RE-USE THE CONICAL SPRING WASHER SCREWS (W700099-S309M), M6X20 MM, TOGETHER WITH REINFORCEMENTS (FLANGE PLATES), -6A523-; AND STUD (E804194-S72), M6X20/M6X20, W10 WASHER, AND WITH REINFORCEMENT, -6A523-. SEE FIGURE 3. ALSO, SEE TSB 92-14-13. CAUTION: CHECK FOR BOTTOMING TO ENSURE CORRECT PARTS WERE INSTALLED DURING PREVIOUS REPAIR. ANY FAILURE TO USE CORRECT FASTENERS CAN RESULT IN AN OIL LEAK AND A REPEAT REPAIR. ALSO CHECK FOR VISIBLE FLATNESS OF THE VALVE COVER RAIL USING A STRAIGHT EDGE. AN OUT OF FLAT RAIL WILL REQUIRE A VALVE COVER REPLACEMENT, OR REPAIR. NOTE: LATER MODEL YEAR VEHICLES (LATE 1992 AND 1993 THROUGH CURRENT), SHOULD HAVE CARRIER GASKETS ALREADY INSTALLED, WITH SHORT SCREWS (W701035-S300), M6XM16MM, WITH CONICAL SPRING WASHERS; AND STUDS (W701041-S300), M6X16/M6X16MM WITH CONICAL SPRING WASHERS; AND SHOULD NOT HAVE REINFORCEMENTS. CHECK THAT THIS HARDWARE WAS INSTALLED AND THEN RE-USE FASTENERS. NOTE: STUD GOES IN UPPER REAR HOLE. ENSURE BOLT HOLES ARE CLEAN AND FREE OF OIL RESIDUE. 3. Install valve cover, rocker arm cover flange plates and bolts. Tighten bolts starting from center bolts and working in crisscross pattern to end bolts. Torque in the same pattern to 6-8 N-m (53-71 lb.in.). See Figure 3. Also, see TSB 92-14-13. 4. Continue reassembly per procedures in appropriate year Service Manual. 5. Fill cooling system using the "Filling and Bleeding the Coolant System" procedure in this TSB article. FILLING AND BLEEDING THE COOLANT SYSTEM WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR CAUSE PERSONAL INJURY. USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. IF POSSIBLE, WAIT UNTIL ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL USING A CLOTH), TURN AND REMOVE IT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1749 In order to bleed the cooling system properly after an initial fill with coolant, it might need up to five (5) cycles of the following: 1. Heating up the system (thermostat open). 2. Ensuring coolant is at least up to the "cold" fill mark of the overflow bottle. 3. Letting coolant cool down (temperature gauge below "N" of normal). 4. Topping off coolant overflow to "cold" mark. 5. Repeating cycle. FILLING WARNING: USE CAUTION WHEN ADDING COOLANT MIXTURE TO RADIATOR TO AVOID HOT COOLANT OR STEAM BLOW OUT FROM THE RADIATOR. NOTE: USE THE FOLLOWING STEPS TO REMOVE AIR FROM THE COOLING SYSTEM AND TO ENSURE A COMPLETE FILL CAN BE ACCOMPLISHED. NOTE: WHEN FILLING A CROSSFLOW RADIATOR, ALLOW TIME FOR THE COOLANT TO FLOW THROUGH THE RADIATOR TUBES TO THE OTHER END TANK TO ENSURE RADIATOR IS FULL. 1. Close radiator draincock and install cylinder block drain plug. 2. Fill the cooling system with a 50/50 ethylene glycol and water mixture. Allow several and then backing off to first stop. This will allow any air to escape and minimize spillage. 4. Slide heater temperature and mode selection levers to maximum heat position. 5. Start engine and allow to operate at fast idle (approximately 2000 rpm) for 3 to 4 minutes. Shut engine off. 6. With engine off, wrap radiator cap with a thick cloth, carefully remove radiator cap and add coolant to bring coolant level up to filler neck seat. 7. Replace radiator cap to fully-installed position. Then, back off to first stop. Operate engine at fast idle until the upper radiator hose is warm (water thermostat opens). To check radiator, shut engine off, wrap radiator cap with thick cloth and carefully remove radiator cap. Add additional coolant if necessary. Replace radiator cap to fully-installed position. 8. Open the small cap on the top of the radiator coolant recovery reservoir. The large cap is for the windshield washer reservoir. NEVER put coolant mixture in windshield washer bottle. 9. Using a suitable suction gun, remove all coolant from radiator coolant recovery reservoir. 10. Add 1 liter (1.1 quart) of 50/50 mixture of ethylene glycol and water to the radiator coolant recovery reservoir. Close small cap. NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON PREVIOUS MODEL YEAR INTAKE MANIFOLDS. USE BOLTS W700166-S309 WITH 1992-94 MANIFOLDS, AND USE BOLTS W702301-S309M WITH 1995 MANIFOLDS. 1995 MANIFOLDS MAY BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A. (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1750 Parts Block OTHER APPLICABLE ARTICLES: 92-14-13, 94-12-13, 94-14-13, 94-18-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950910A Replace Lower Intake 3.9 Hrs. Manifold Gasket - Aerostar (Not To Be Used With Operations D, E, Or F) 950910B Replace Lower Intake 2.7 Hrs. Manifold Gasket - Ranger, Explorer (Not To Be Used With Operations G, H, Or I) 9509100 Additional Time To 0.2 Hr. Replace Lower Intake Manifold - All Vehicles 950910D Replace Right Side 5.6 Hrs. Cylinder Head Gasket - Aerostar (Not To Be Used With Operation A) 950910E Replace Left Side Cylinder 5.4 Hrs. Head Gasket - Aerostar (Not To Be Used With Operation A) 950910F Replace Both Cylinder 7.5 Hrs. Head Gaskets - Aerostar (Not To Be Used With Operation A) 95O91OG Replace Right Side 3.8 Hrs. Cylinder Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910H Replace Left Side Cylinder 3.5 Hrs. Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910I Replace Both Cylinder 5.0 Hrs. Head Gaskets - Ranger, Explorer (Not To Be Used With Operation B) 95O91OJ Additional Time If 0.1 Hr. Equipped With Speed Control - All Vehicles (May Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1751 Only Be Used With Operations A Or B) 950910K Additional Time If 0.3 Hr. Equipped With A/C - Aerostar (Not To Be Used With Operation A) 95O910L Additional Time If 0.8 Hr. Equipped With A/C - Ranger, Explorer (Not To Be Used With Operation B) DEALER CODING CONDITION BASIC PART NO. CODE 6049 57 OASIS CODES: 402000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 1752 Intake Manifold: Specifications Lower Intake Manifold Bolt Tightening Sequence Lower Intake Manifold Bolts Are Tightened In Sequence And In 4 Steps Step 1 .................................................................................................................................................. ............................................ 4-8 Nm (3-6 ft lb) Step 2 ......................................................................... ................................................................................................................. 8-15 Nm (6-11 ft lb) Step 3 .............................................................................................................................................................. ........................ 15-21 Nm (11-15 ft lb) Step 4 ..................................................................................... ................................................................................................. 21-25 Nm (15-18 ft lb) Upper Intake Manifold Retaining Nuts ............................................................................................................................................. 20-25 Nm (15-18 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold: Service and Repair Lower * THIS ARTICLE REFLECTS CHANGES MADE BY TSB #94-18-10, DATED September 07, 1994 REMOVAL NOTE: The intake manifold is a four piece assembly consisting of the upper intake manifold, the throttle body, the fuel supply manifold and the lower intake manifold. 1. Disconnect the battery ground cable at the battery. 2. Remove the air cleaner air intake duct from the throttle body. 3. Remove the snow/ice shield and disconnect the throttle cable and bracket assembly. 4. Disconnect all vacuum hoses from the fittings on the upper intake manifold. 5. Disconnect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and injectors. 6. Relieve fuel system pressure. 7. Disconnect the fuel supply and return lines at the fuel supply manifold. Coil Mounting Bracket 8. Remove the bolts securing the ignition coil pack and bracket assembly to the upper intake manifold. 9. Remove the six nuts securing the upper intake manifold and remove the upper manifold. 10. Remove the valve rocker arm covers. 11. Remove the intake manifold attaching bolts and nuts. Tap the intake manifold lightly with a plastic mallet to break the gasket seal, and lift off the intake manifold assembly. 12. Remove all old gasket material, and sealing compound. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 1755 Lower Intake Manifold 1. Apply Silicone Sealer (Loctite 598, F1AZ-19562-A or equivalent) to the block and cylinder head mating surfaces at the four corners shown. Install the intake manifold gaskets and again apply sealer to the four corner locations. NOTE: Once applied, the silicone sealer will set-up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied. Lower Intake Manifold Bolt Tightening Sequence 2. Position the intake manifold on the two guide studs and install the nuts and bolts hand tight. Tighten the intake manifold bolts in four stages following the sequence shown. a. 4-8 Nm (3-6 ft lb) b. 8-15 Nm (6-11 ft lb) c. 15-21 Nm (11-15 ft lb) d. 21-25 Nm (15-18 ft lb) 3. Apply Silicone Sealer (Loctite 598, F1AZ-19562-A or equivalent) to the four locations at the joint where the intake manifold and cylinder heads meet. 4. Position valve rocker arm cover gasket in each cover and install valve rocker arm covers. Tighten rocker arm cover bolts evenly to 6-8 Nm (4.5-5.9 ft lb). NOTE: Valve rocker arm covers are tightened in 2 steps. Tighten bolts to specification. Two minutes later, tighten bolts to the same specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 1756 Upper Intake Manifold 5. Install upper intake manifold and tighten nuts to 20-25 Nm (15-18 ft lb). 6. Install the ignition coil pack and bracket assembly. 7. Connect the fuel supply and return lines at the fuel supply manifold. 8. Connect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and injectors. 9. Connect all vacuum hoses to the fittings on the upper intake manifold. 10. Install the throttle cable and bracket assembly and the snow/ice shield to the throttle body. 11. Connect the air cleaner air intake duct to the throttle body. 12. Fill and bleed the cooling system. 13. Connect the battery ground cable at the battery. 14. Check for fuel system and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower > Page 1757 Intake Manifold: Service and Repair Upper Intake Manifold REMOVAL 1. Disconnect the electrical connectors at the idle air control valve, throttle position sensor and intake air temperature sensor. 2. Remove the fuel supply manifold shield to expose the throttle linkage. Remove the throttle cable bracket and disconnect the cable from the ball stud on the throttle body. 3. Remove the engine air cleaner intake tube and duct from air cleaner to throttle body. 4. Disconnect the upper intake manifold vacuum connectors. 5. Disconnect the PCV valve from the rocker cover. 6. Disconnect the spark plug wires from the comb at the rear of the intake manifold. 7. Remove the canister purge line from the fitting in the throttle housing. 8. Remove the bolt retaining the engine oil dipstick tube. 9. Remove the bolt which retains the A/C line at the upper rear of the upper intake manifold. 10. Remove the six upper intake manifold retaining bolts. 11. Remove the upper intake manifold and throttle body as an assembly from the lower intake and fuel injection supply manifolds. INSTALLATION NOTE: If the lower intake manifold was removed, fill and bleed the cooling system. 1. Clean and inspect the mounting faces of the fuel injection supply manifold and upper intake manifold. Upper Intake Manifold 2. Position a new gasket on the mounting studs. 3. Install the upper intake manifold on the studs. 4. Install six upper intake manifold retaining nuts. Tighten to 20-25 Nm (15-18 ft lb). 5. Connect the spark plug wires to the retainer comb at the rear of the intake manifold. 6. Attach the A/C line retainer and automatic transmission vacuum line retainer at the upper intake manifold. 7. Install the canister purge line on the throttle body fitting. 8. Connect vacuum lines to the vacuum tree. Connect the electrical connector at the throttle position sensor and idle air control valve and intake air temperature sensor. 9. Install the PCV valve in the grommet at the rear of the right rocker cover. 10. Attach the engine oil dipstick tube to the upper intake manifold. 11. Attach the throttle cable bracket to the upper intake manifold, then connect the throttle cable to the ball stud and install the fuel supply manifold shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Description and Operation > Page 1762 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Oil Pressure Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Oil Pressure Gauge Inaccurate Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 1768 Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 1769 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Relays and Modules - Engine > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Rear Main Oil Seal Replacement - Service Tip Crankshaft Main Bearing Seal: Technical Service Bulletins Rear Main Oil Seal Replacement Service Tip Article No. 95-1-8 01/16/95 ^ LEAK - REAR MAIN OIL SEAL REPLACEMENT - VEHICLES WITH 4.0L ENGINES - SERVICE TIP ^ REAR MAIN SEAL - 4.0L - NEW INSTALLATION TOOL LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: A redesigned tool for installation of rear main seals is available and must be used for all rear main seal replacements. Prior released tools (T72C-6165) and (T72C-6165-R) must not be used. Usage of obsolete tools may cause oil leaks due to seal damage, crankshaft journal damage or mispositioning of the seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Rear Main Oil Seal Replacement - Service Tip > Page 1782 ACTION: If an oil leak is detected, refer to TSB 94-12-13 for proper diagnosis of the oil leak. If, after diagnosis, it is determined that a new rear main seal needs to be installed, use the procedure found in TSB 94-12-13. Be sure to use the new Rear Oil Seal Replacer Tool (T95T-6701-A) when installing a new rear main seal. Refer to Figure 1 for more details. OTHER APPLICABLE ARTICLES: 94-12-13 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 1783 Crankshaft Main Bearing Seal: Service and Repair *** THIS ARTICLE REFLECTS CHANGES MADE BY TSB 9518 DATED JANUARY 16, 1995 NOTE: Use dye and black light as to determine if oil leak is from oil pan gasket or crankshaft rear oil seal. REMOVAL 1. Remove the transmission. 2. Remove flywheel. Rear Main Seal Removal 3. Use an awl to punch two holes in the crankshaft rear oil seal. Punch the holes on opposite sides of the crankshaft and just above the bearing cap-to-cylinder block split line. Install a sheet metal screw in each hole. Use two large screwdrivers or small pry bars and pry against both screws at the same time to remove the crankshaft rear oil seal. It may be necessary to place small blocks of wood against the cylinder block to provide a fulcrum point for the pry bars. Use caution throughout this procedure to avoid scratching or otherwise damaging the crankshaft oil seal surface. 4. Clean the oil seal recess in the cylinder block and main bearing cap. Inspect and clean the oil seal contact surface on the crankshaft. INSTALLATION CAUTION: This installation procedure requires the use of hand tools only. The use of power tools or hammering on the installer can damage the sleeve and seal. Rear Main Seal Installation Tool 1. Attach the rear crankshaft adapter to the rear of the crankshaft using the supplied mounting screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 1784 Rear Main Oil Seal Installation 2. Apply a few drops of clean engine oil to the inboard side of the seal/sleeve at the area where the seal contacts the sleeve. 3. Apply a very light film of clean engine oil on the inner diameter of the sleeve and outer diameter of seal. 4. Slide the seal/sleeve over the rear crankshaft seal adapter with flange to the rear of the engine. NOTE: It is normal for the seal to sit approximately 0.76 mm (0.030 inch) deeper than the sleeve flange. Do not adjust. 5. Use the rear crankshaft seal replacer and supplied bolt to push the rear seal into the cylinder block. 6. Remove the rear crankshaft seal adapter. 7. Install flywheel. Tighten flywheel bolts in two stages. a. First stage - 12-15 Nm (9-11 ft lb) b. Second stage - 68-74 Nm (50-55 ft lb) 8. Install transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss Intake Manifold Gasket: Customer Interest Cooling System - Coolant Loss Article No. 95-9-10 05/08/95 ^ COOLING SYSTEM - LOSS OF COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE ^ LEAKS - COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER, RANGER ISSUE: Coolant loss, with no visible sign of leakage, may occur on some vehicles. This may be due to internal leaks from a failed intake manifold gasket caused by loose intake manifold bolts, a fouled intake manifold, pitting/corrosion, or loose cylinder head bolts. ACTION: Refer to the following procedures for service details. NOTE: DUE TO AIR BEING TRAPPED IN THE COOLING SYSTEM, IT IS NOT UNUSUAL TO ADD 44 OZ (118-207 ML) COOLANT UP TO 7500 MILES (12,000 KM) AFTER INITIAL FILL. INSPECTION PROCEDURE 1. Run the engine for 10 minutes, or as required, to build pressure in the cooling system for a leak inspection. Examine the radiator, side tanks, coolant recovery bottle, hoses and connections, intake manifold, cylinder heads and block for external coolant leaks. If no external leak can be found, then the concern may be with the lower intake manifold gasket, intake manifold pitting/corrosion, or with low cylinder head bolt torque. 2. Measure the cylinder head bolt torque. If torque is less than 80 N-m (59 lb.ft.), replace Cylinder Head Gasket (F5TZ-6051-A RH, and F5TZ-6051-B LH) using the procedure in this TSB article. 3. If coolant loss continues, even with proper head bolt torque, remove intake manifold and remove all old gasket material and any coolant residue with a soft non-metallic or aluminum wire brush. Inspect manifold for corrosion/erosion/pitting damage at the four (4) water passages (Figure 1). If damaged, the intake manifold must be replaced. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1793 MANIFOLD MUST BE REPLACED. 4. Replace the lower intake manifold gasket with the new Carrier-type Intake Manifold Gasket (F5TZ-9439-A). Use the procedures found in this TSB article. DISASSEMBLY PROCEDURE - INTAKE AND CYLINDER HEAD GASKETS Service the intake manifold (lower) and cylinder head gaskets per the appropriate Powertrain/Drivetrain Service Manual, when required. INSTALLATION ASSEMBLY PROCEDURE AFTER REMOVING BOTH CYLINDER HEAD AND INTAKE MANIFOLD 1. Remove all old gasket material with a soft non-metallic or aluminum wire brush. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. 2. Before installing the new gasket, remove all old sealer from the intake, heads and block surfaces, and check for proper condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. NOTE: THE 4.0L ENGINE SHOULD ALWAYS BE ASSEMBLED USING NEW CYLINDER HEAD BOLTS. 3. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Position the cylinder heads onto the head gaskets and locating dowels (Figure 4). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1794 NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (AS IN ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (E805676-S72). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W7OOl 66-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECEIVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE CYLINDER HEAD(S) AND INTAKE MANIFOLD ARE TORQUED ALTERNATELY AND IN SEQUENCE TO ENSURE CORRECT FIT AND GASKET CRUSH. FAILURE TO FOLLOW COMPLETE TORQUE SEQUENCE WILL CAUSE FOLLOW-UP REPAIR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1795 4. Install and torque cylinder head bolts, in the sequence shown. to 30 N-m (22 lb.ft) (Figure 5). NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 5. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). 6. Position the gasket with the help of the two (2) temporary guide studs (Item 3 Figure 6) located in Positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the tour (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1796 7. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Torque the intake manifold bolts, in sequence, to 4 N-m (3 lb.ft.) (Figure 7). Replace the two (2) studs with bolts (save the studs for use when necessary on future jobs). NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 8. Torque the cylinder head bolts, in sequence, to 70 N-m (52 lb.ft.) (Figure 5). 9. Torque the intake manifold bolts, in sequence, to 8 N-m (6 lb.ft.) (Figure 7). 10. For the final cylinder head torque step, rotate the cylinder head bolts 90 degrees in sequence (Figure 5). 11. If using bolts with a captive washer (1995 manifold), finish tightening the intake manifold, in sequence, to 15 N-m (11 lb.ft.). If using bolts without a captive washer (1990-94 manifold), tighten an additional step to 21 N-m (15 lb.ft.). 12. Install the valve push rods. Install the rocker arms as outlined in the Service Manual. 13. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. INSTALLATION PROCEDURE AFTER REMOVING ONLY THE INTAKE MANIFOLD 1. Before installing the new gaskets, remove all old sealer from the intake, heads and block surfaces, and check for proper surface condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE MANIFOLD MUST BE REPLACED. NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (W701104-S309). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W700166-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECIEVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 2. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1797 3. Position the gasket with the help of the two (2) temporary guide studs (Item 3, Figure 6) located in positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the four (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. 4. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Tighten the intake manifold in stages using the following torques and the sequence shown in Figure 7. a. 4 N-m (3 lb.ft.) NOTE: REPLACE THE TWO (2) STUDS WITH BOLTS (SAVE THE STUDS FOR USE WHEN NECESSARY ON FUTURE JOBS). b. 8 N-m (6 lb.ft.) c. 15 N-m (11 lb.ft.) NOTE: STOP HERE IF THE INTAKE MANIFOLD BEING INSTALLED IS A 1995 (BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A OR WIDE AREA FOR THE BOLT HOLE SPOTFACE). THE FOLLOWING STEP APPLIES ONLY TO PRIOR YEAR MANIFOLDS. d. 21 N-m (15 lb.ft.) NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 5. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. VALVE COVER AND GASKET INSTALLATION PROCEDURE 1. Clean valve cover, intake manifold, cylinder head gasket surfaces and threaded bolt holes. NOTE: SINCE SILICONE RUBBER SEALANT WILL SET-UP IN 15 MINUTES, APPLY TO ONE (1) VALVE COVER AT A TIME, IF YOU ARE INSTALLING BOTH COVERS. 2. Apply a small amount (peanut size) of Silicone Rubber Sealant, Loctite 598 (F1AZ-19562-A), or equivalent, to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1798 ^ The four (4) manifold locations at the joint where the intake manifold and the cylinder heads meet (Figure 3, Position A). ^ Any casting irregularity on the gasket sealing area of the cylinder head(s). NOTE: IF 1992 VEHICLES HAVE VALVE COVER GASKETS OF THE CORK TYPE, THESE GASKETS MUST BE REPLACED WITH METAL-TYPE (CARRIER) GASKET. THE NEW TYPE GASKET IS A THINNER GASKET, THEREFORE TO PREVENT BOTTOMING IT IS IMPORTANT TO RE-USE THE CONICAL SPRING WASHER SCREWS (W700099-S309M), M6X20 MM, TOGETHER WITH REINFORCEMENTS (FLANGE PLATES), -6A523-; AND STUD (E804194-S72), M6X20/M6X20, W10 WASHER, AND WITH REINFORCEMENT, -6A523-. SEE FIGURE 3. ALSO, SEE TSB 92-14-13. CAUTION: CHECK FOR BOTTOMING TO ENSURE CORRECT PARTS WERE INSTALLED DURING PREVIOUS REPAIR. ANY FAILURE TO USE CORRECT FASTENERS CAN RESULT IN AN OIL LEAK AND A REPEAT REPAIR. ALSO CHECK FOR VISIBLE FLATNESS OF THE VALVE COVER RAIL USING A STRAIGHT EDGE. AN OUT OF FLAT RAIL WILL REQUIRE A VALVE COVER REPLACEMENT, OR REPAIR. NOTE: LATER MODEL YEAR VEHICLES (LATE 1992 AND 1993 THROUGH CURRENT), SHOULD HAVE CARRIER GASKETS ALREADY INSTALLED, WITH SHORT SCREWS (W701035-S300), M6XM16MM, WITH CONICAL SPRING WASHERS; AND STUDS (W701041-S300), M6X16/M6X16MM WITH CONICAL SPRING WASHERS; AND SHOULD NOT HAVE REINFORCEMENTS. CHECK THAT THIS HARDWARE WAS INSTALLED AND THEN RE-USE FASTENERS. NOTE: STUD GOES IN UPPER REAR HOLE. ENSURE BOLT HOLES ARE CLEAN AND FREE OF OIL RESIDUE. 3. Install valve cover, rocker arm cover flange plates and bolts. Tighten bolts starting from center bolts and working in crisscross pattern to end bolts. Torque in the same pattern to 6-8 N-m (53-71 lb.in.). See Figure 3. Also, see TSB 92-14-13. 4. Continue reassembly per procedures in appropriate year Service Manual. 5. Fill cooling system using the "Filling and Bleeding the Coolant System" procedure in this TSB article. FILLING AND BLEEDING THE COOLANT SYSTEM WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR CAUSE PERSONAL INJURY. USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. IF POSSIBLE, WAIT UNTIL ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL USING A CLOTH), TURN AND REMOVE IT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1799 In order to bleed the cooling system properly after an initial fill with coolant, it might need up to five (5) cycles of the following: 1. Heating up the system (thermostat open). 2. Ensuring coolant is at least up to the "cold" fill mark of the overflow bottle. 3. Letting coolant cool down (temperature gauge below "N" of normal). 4. Topping off coolant overflow to "cold" mark. 5. Repeating cycle. FILLING WARNING: USE CAUTION WHEN ADDING COOLANT MIXTURE TO RADIATOR TO AVOID HOT COOLANT OR STEAM BLOW OUT FROM THE RADIATOR. NOTE: USE THE FOLLOWING STEPS TO REMOVE AIR FROM THE COOLING SYSTEM AND TO ENSURE A COMPLETE FILL CAN BE ACCOMPLISHED. NOTE: WHEN FILLING A CROSSFLOW RADIATOR, ALLOW TIME FOR THE COOLANT TO FLOW THROUGH THE RADIATOR TUBES TO THE OTHER END TANK TO ENSURE RADIATOR IS FULL. 1. Close radiator draincock and install cylinder block drain plug. 2. Fill the cooling system with a 50/50 ethylene glycol and water mixture. Allow several and then backing off to first stop. This will allow any air to escape and minimize spillage. 4. Slide heater temperature and mode selection levers to maximum heat position. 5. Start engine and allow to operate at fast idle (approximately 2000 rpm) for 3 to 4 minutes. Shut engine off. 6. With engine off, wrap radiator cap with a thick cloth, carefully remove radiator cap and add coolant to bring coolant level up to filler neck seat. 7. Replace radiator cap to fully-installed position. Then, back off to first stop. Operate engine at fast idle until the upper radiator hose is warm (water thermostat opens). To check radiator, shut engine off, wrap radiator cap with thick cloth and carefully remove radiator cap. Add additional coolant if necessary. Replace radiator cap to fully-installed position. 8. Open the small cap on the top of the radiator coolant recovery reservoir. The large cap is for the windshield washer reservoir. NEVER put coolant mixture in windshield washer bottle. 9. Using a suitable suction gun, remove all coolant from radiator coolant recovery reservoir. 10. Add 1 liter (1.1 quart) of 50/50 mixture of ethylene glycol and water to the radiator coolant recovery reservoir. Close small cap. NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON PREVIOUS MODEL YEAR INTAKE MANIFOLDS. USE BOLTS W700166-S309 WITH 1992-94 MANIFOLDS, AND USE BOLTS W702301-S309M WITH 1995 MANIFOLDS. 1995 MANIFOLDS MAY BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A. (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1800 Parts Block OTHER APPLICABLE ARTICLES: 92-14-13, 94-12-13, 94-14-13, 94-18-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950910A Replace Lower Intake 3.9 Hrs. Manifold Gasket - Aerostar (Not To Be Used With Operations D, E, Or F) 950910B Replace Lower Intake 2.7 Hrs. Manifold Gasket - Ranger, Explorer (Not To Be Used With Operations G, H, Or I) 9509100 Additional Time To 0.2 Hr. Replace Lower Intake Manifold - All Vehicles 950910D Replace Right Side 5.6 Hrs. Cylinder Head Gasket - Aerostar (Not To Be Used With Operation A) 950910E Replace Left Side Cylinder 5.4 Hrs. Head Gasket - Aerostar (Not To Be Used With Operation A) 950910F Replace Both Cylinder 7.5 Hrs. Head Gaskets - Aerostar (Not To Be Used With Operation A) 95O91OG Replace Right Side 3.8 Hrs. Cylinder Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910H Replace Left Side Cylinder 3.5 Hrs. Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910I Replace Both Cylinder 5.0 Hrs. Head Gaskets - Ranger, Explorer (Not To Be Used With Operation B) 95O91OJ Additional Time If 0.1 Hr. Equipped With Speed Control - All Vehicles (May Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Customer Interest for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1801 Only Be Used With Operations A Or B) 950910K Additional Time If 0.3 Hr. Equipped With A/C - Aerostar (Not To Be Used With Operation A) 95O910L Additional Time If 0.8 Hr. Equipped With A/C - Ranger, Explorer (Not To Be Used With Operation B) DEALER CODING CONDITION BASIC PART NO. CODE 6049 57 OASIS CODES: 402000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss Intake Manifold Gasket: All Technical Service Bulletins Cooling System - Coolant Loss Article No. 95-9-10 05/08/95 ^ COOLING SYSTEM - LOSS OF COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE ^ LEAKS - COOLANT - 4.0L ENGINE - REVISED INTAKE MANIFOLD GASKET AND INSTALLATION PROCEDURE LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER, RANGER ISSUE: Coolant loss, with no visible sign of leakage, may occur on some vehicles. This may be due to internal leaks from a failed intake manifold gasket caused by loose intake manifold bolts, a fouled intake manifold, pitting/corrosion, or loose cylinder head bolts. ACTION: Refer to the following procedures for service details. NOTE: DUE TO AIR BEING TRAPPED IN THE COOLING SYSTEM, IT IS NOT UNUSUAL TO ADD 44 OZ (118-207 ML) COOLANT UP TO 7500 MILES (12,000 KM) AFTER INITIAL FILL. INSPECTION PROCEDURE 1. Run the engine for 10 minutes, or as required, to build pressure in the cooling system for a leak inspection. Examine the radiator, side tanks, coolant recovery bottle, hoses and connections, intake manifold, cylinder heads and block for external coolant leaks. If no external leak can be found, then the concern may be with the lower intake manifold gasket, intake manifold pitting/corrosion, or with low cylinder head bolt torque. 2. Measure the cylinder head bolt torque. If torque is less than 80 N-m (59 lb.ft.), replace Cylinder Head Gasket (F5TZ-6051-A RH, and F5TZ-6051-B LH) using the procedure in this TSB article. 3. If coolant loss continues, even with proper head bolt torque, remove intake manifold and remove all old gasket material and any coolant residue with a soft non-metallic or aluminum wire brush. Inspect manifold for corrosion/erosion/pitting damage at the four (4) water passages (Figure 1). If damaged, the intake manifold must be replaced. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1807 MANIFOLD MUST BE REPLACED. 4. Replace the lower intake manifold gasket with the new Carrier-type Intake Manifold Gasket (F5TZ-9439-A). Use the procedures found in this TSB article. DISASSEMBLY PROCEDURE - INTAKE AND CYLINDER HEAD GASKETS Service the intake manifold (lower) and cylinder head gaskets per the appropriate Powertrain/Drivetrain Service Manual, when required. INSTALLATION ASSEMBLY PROCEDURE AFTER REMOVING BOTH CYLINDER HEAD AND INTAKE MANIFOLD 1. Remove all old gasket material with a soft non-metallic or aluminum wire brush. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. 2. Before installing the new gasket, remove all old sealer from the intake, heads and block surfaces, and check for proper condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. NOTE: THE 4.0L ENGINE SHOULD ALWAYS BE ASSEMBLED USING NEW CYLINDER HEAD BOLTS. 3. Position cylinder head gaskets on cylinder block. Install cylinder head locating dowels. Position the cylinder heads onto the head gaskets and locating dowels (Figure 4). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1808 NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (AS IN ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (E805676-S72). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W7OOl 66-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECEIVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE CYLINDER HEAD(S) AND INTAKE MANIFOLD ARE TORQUED ALTERNATELY AND IN SEQUENCE TO ENSURE CORRECT FIT AND GASKET CRUSH. FAILURE TO FOLLOW COMPLETE TORQUE SEQUENCE WILL CAUSE FOLLOW-UP REPAIR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1809 4. Install and torque cylinder head bolts, in the sequence shown. to 30 N-m (22 lb.ft) (Figure 5). NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 5. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). 6. Position the gasket with the help of the two (2) temporary guide studs (Item 3 Figure 6) located in Positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the tour (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1810 7. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Torque the intake manifold bolts, in sequence, to 4 N-m (3 lb.ft.) (Figure 7). Replace the two (2) studs with bolts (save the studs for use when necessary on future jobs). NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 8. Torque the cylinder head bolts, in sequence, to 70 N-m (52 lb.ft.) (Figure 5). 9. Torque the intake manifold bolts, in sequence, to 8 N-m (6 lb.ft.) (Figure 7). 10. For the final cylinder head torque step, rotate the cylinder head bolts 90 degrees in sequence (Figure 5). 11. If using bolts with a captive washer (1995 manifold), finish tightening the intake manifold, in sequence, to 15 N-m (11 lb.ft.). If using bolts without a captive washer (1990-94 manifold), tighten an additional step to 21 N-m (15 lb.ft.). 12. Install the valve push rods. Install the rocker arms as outlined in the Service Manual. 13. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. INSTALLATION PROCEDURE AFTER REMOVING ONLY THE INTAKE MANIFOLD 1. Before installing the new gaskets, remove all old sealer from the intake, heads and block surfaces, and check for proper surface condition. Clean all exposed areas very thoroughly with Metal Surface Cleaner (F4AZ-19A536-RA) or denatured alcohol. CAUTION: DO NOT USE A SAND DISK OR SIMILAR POWER TOOL. IF THE INTAKE MANIFOLD SURFACE IS PITTED (FIGURE 1), THEN THE MANIFOLD MUST BE REPLACED. NOTE: IF THE ENGINE RECEIVED HAS BOLTS INSTEAD OF GUIDE STUDS (ITEM 3, FIGURE 6), THEN TEMPORARILY REPLACE BOLTS WITH GUIDE STUDS (W701104-S309). IF GUIDE STUDS ARE NOT IN STOCK, FABRICATE BY REMOVING THE HEADS FROM TWO (2) BOLTS (W700166-S309). INSTALL THEM SNUGLY IN THE CYLINDER BLOCK HOLES THAT MATCH HOLES 3 AND 4 (FIGURE 7). IF GUIDE STUDS WERE ON THE VEHICLE RECIEVED, THEN LOOSEN THE STUDS 1/2 TURN BEFORE PROCEEDING. NOTE: THE SILICONE SEALER, APPLIED IN THE FOLLOWING STEP, WILL SET-UP IN APPROXIMATELY 15 MINUTES. THE INTAKE MANIFOLD MUST BE INSTALLED IMMEDIATELY AFTER THE SEALER IS APPLIED. 2. Apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the bottom side of the gasket at the four (4) corners (Figure 2). The sealer should be applied between the ridges (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1811 3. Position the gasket with the help of the two (2) temporary guide studs (Item 3, Figure 6) located in positions 3 and 4 (Figure 7), and slide the gasket down to its final position in the valley. Then apply a small amount (peanut size) of Silicone Rubber Sealer, Loctite 598 (F1AZ-19562-A) on the top side of the gasket at the four (4) corners between the ridges (Figure 2). NOTE: IF INTAKE MANIFOLD REPLACEMENT IS REQUIRED AS DETERMINED FROM EARLIER INSPECTION PROCEDURE, AND WHEN REPLACING WITH A 1995 MANIFOLD, DIFFERENT MANIFOLD BOLTS ARE TO BE USED AS WHEN REPLACING WITH A PREVIOUS YEAR MANIFOLD. ALSO, AN ADDITIONAL TORQUE STEP IS REQUIRED WITH THE 1992-94 MANIFOLD. THE 1995 MANIFOLD CAN BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A, (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. 4. Position the lower intake manifold on the two (2) guide studs and install the nuts and bolts handtight. See Figures 6 and 8 for proper bolt selection, depending on the manifold year. Tighten the intake manifold in stages using the following torques and the sequence shown in Figure 7. a. 4 N-m (3 lb.ft.) NOTE: REPLACE THE TWO (2) STUDS WITH BOLTS (SAVE THE STUDS FOR USE WHEN NECESSARY ON FUTURE JOBS). b. 8 N-m (6 lb.ft.) c. 15 N-m (11 lb.ft.) NOTE: STOP HERE IF THE INTAKE MANIFOLD BEING INSTALLED IS A 1995 (BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A OR WIDE AREA FOR THE BOLT HOLE SPOTFACE). THE FOLLOWING STEP APPLIES ONLY TO PRIOR YEAR MANIFOLDS. d. 21 N-m (15 lb.ft.) NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON INTAKE MANIFOLDS OF PREVIOUS MODEL YEARS. 5. Install the valve covers as outlined in "Valve Cover and Gasket Installation Procedure" in this TSB article. VALVE COVER AND GASKET INSTALLATION PROCEDURE 1. Clean valve cover, intake manifold, cylinder head gasket surfaces and threaded bolt holes. NOTE: SINCE SILICONE RUBBER SEALANT WILL SET-UP IN 15 MINUTES, APPLY TO ONE (1) VALVE COVER AT A TIME, IF YOU ARE INSTALLING BOTH COVERS. 2. Apply a small amount (peanut size) of Silicone Rubber Sealant, Loctite 598 (F1AZ-19562-A), or equivalent, to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1812 ^ The four (4) manifold locations at the joint where the intake manifold and the cylinder heads meet (Figure 3, Position A). ^ Any casting irregularity on the gasket sealing area of the cylinder head(s). NOTE: IF 1992 VEHICLES HAVE VALVE COVER GASKETS OF THE CORK TYPE, THESE GASKETS MUST BE REPLACED WITH METAL-TYPE (CARRIER) GASKET. THE NEW TYPE GASKET IS A THINNER GASKET, THEREFORE TO PREVENT BOTTOMING IT IS IMPORTANT TO RE-USE THE CONICAL SPRING WASHER SCREWS (W700099-S309M), M6X20 MM, TOGETHER WITH REINFORCEMENTS (FLANGE PLATES), -6A523-; AND STUD (E804194-S72), M6X20/M6X20, W10 WASHER, AND WITH REINFORCEMENT, -6A523-. SEE FIGURE 3. ALSO, SEE TSB 92-14-13. CAUTION: CHECK FOR BOTTOMING TO ENSURE CORRECT PARTS WERE INSTALLED DURING PREVIOUS REPAIR. ANY FAILURE TO USE CORRECT FASTENERS CAN RESULT IN AN OIL LEAK AND A REPEAT REPAIR. ALSO CHECK FOR VISIBLE FLATNESS OF THE VALVE COVER RAIL USING A STRAIGHT EDGE. AN OUT OF FLAT RAIL WILL REQUIRE A VALVE COVER REPLACEMENT, OR REPAIR. NOTE: LATER MODEL YEAR VEHICLES (LATE 1992 AND 1993 THROUGH CURRENT), SHOULD HAVE CARRIER GASKETS ALREADY INSTALLED, WITH SHORT SCREWS (W701035-S300), M6XM16MM, WITH CONICAL SPRING WASHERS; AND STUDS (W701041-S300), M6X16/M6X16MM WITH CONICAL SPRING WASHERS; AND SHOULD NOT HAVE REINFORCEMENTS. CHECK THAT THIS HARDWARE WAS INSTALLED AND THEN RE-USE FASTENERS. NOTE: STUD GOES IN UPPER REAR HOLE. ENSURE BOLT HOLES ARE CLEAN AND FREE OF OIL RESIDUE. 3. Install valve cover, rocker arm cover flange plates and bolts. Tighten bolts starting from center bolts and working in crisscross pattern to end bolts. Torque in the same pattern to 6-8 N-m (53-71 lb.in.). See Figure 3. Also, see TSB 92-14-13. 4. Continue reassembly per procedures in appropriate year Service Manual. 5. Fill cooling system using the "Filling and Bleeding the Coolant System" procedure in this TSB article. FILLING AND BLEEDING THE COOLANT SYSTEM WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR CAUSE PERSONAL INJURY. USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. IF POSSIBLE, WAIT UNTIL ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL USING A CLOTH), TURN AND REMOVE IT. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1813 In order to bleed the cooling system properly after an initial fill with coolant, it might need up to five (5) cycles of the following: 1. Heating up the system (thermostat open). 2. Ensuring coolant is at least up to the "cold" fill mark of the overflow bottle. 3. Letting coolant cool down (temperature gauge below "N" of normal). 4. Topping off coolant overflow to "cold" mark. 5. Repeating cycle. FILLING WARNING: USE CAUTION WHEN ADDING COOLANT MIXTURE TO RADIATOR TO AVOID HOT COOLANT OR STEAM BLOW OUT FROM THE RADIATOR. NOTE: USE THE FOLLOWING STEPS TO REMOVE AIR FROM THE COOLING SYSTEM AND TO ENSURE A COMPLETE FILL CAN BE ACCOMPLISHED. NOTE: WHEN FILLING A CROSSFLOW RADIATOR, ALLOW TIME FOR THE COOLANT TO FLOW THROUGH THE RADIATOR TUBES TO THE OTHER END TANK TO ENSURE RADIATOR IS FULL. 1. Close radiator draincock and install cylinder block drain plug. 2. Fill the cooling system with a 50/50 ethylene glycol and water mixture. Allow several and then backing off to first stop. This will allow any air to escape and minimize spillage. 4. Slide heater temperature and mode selection levers to maximum heat position. 5. Start engine and allow to operate at fast idle (approximately 2000 rpm) for 3 to 4 minutes. Shut engine off. 6. With engine off, wrap radiator cap with a thick cloth, carefully remove radiator cap and add coolant to bring coolant level up to filler neck seat. 7. Replace radiator cap to fully-installed position. Then, back off to first stop. Operate engine at fast idle until the upper radiator hose is warm (water thermostat opens). To check radiator, shut engine off, wrap radiator cap with thick cloth and carefully remove radiator cap. Add additional coolant if necessary. Replace radiator cap to fully-installed position. 8. Open the small cap on the top of the radiator coolant recovery reservoir. The large cap is for the windshield washer reservoir. NEVER put coolant mixture in windshield washer bottle. 9. Using a suitable suction gun, remove all coolant from radiator coolant recovery reservoir. 10. Add 1 liter (1.1 quart) of 50/50 mixture of ethylene glycol and water to the radiator coolant recovery reservoir. Close small cap. NOTE: MODEL YEAR 1995 BOLTS WITH CAPTIVE WASHERS ARE NOT USABLE ON PREVIOUS MODEL YEAR INTAKE MANIFOLDS. USE BOLTS W700166-S309 WITH 1992-94 MANIFOLDS, AND USE BOLTS W702301-S309M WITH 1995 MANIFOLDS. 1995 MANIFOLDS MAY BE IDENTIFIED BY TWO METHODS: (1) THE BLUE DOT BENEATH THE SUFFIX OF PART NUMBER FOTZ-9424-A. (2) THE SPOTFACE AREAS AS PER FIGURE 8. USE THIS METHOD IF NO BLUE DOT IS VISIBLE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1814 Parts Block OTHER APPLICABLE ARTICLES: 92-14-13, 94-12-13, 94-14-13, 94-18-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 950910A Replace Lower Intake 3.9 Hrs. Manifold Gasket - Aerostar (Not To Be Used With Operations D, E, Or F) 950910B Replace Lower Intake 2.7 Hrs. Manifold Gasket - Ranger, Explorer (Not To Be Used With Operations G, H, Or I) 9509100 Additional Time To 0.2 Hr. Replace Lower Intake Manifold - All Vehicles 950910D Replace Right Side 5.6 Hrs. Cylinder Head Gasket - Aerostar (Not To Be Used With Operation A) 950910E Replace Left Side Cylinder 5.4 Hrs. Head Gasket - Aerostar (Not To Be Used With Operation A) 950910F Replace Both Cylinder 7.5 Hrs. Head Gaskets - Aerostar (Not To Be Used With Operation A) 95O91OG Replace Right Side 3.8 Hrs. Cylinder Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910H Replace Left Side Cylinder 3.5 Hrs. Head Gasket - Ranger, Explorer (Not To Be Used With Operation B) 950910I Replace Both Cylinder 5.0 Hrs. Head Gaskets - Ranger, Explorer (Not To Be Used With Operation B) 95O91OJ Additional Time If 0.1 Hr. Equipped With Speed Control - All Vehicles (May Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 95910 > May > 95 > Cooling System - Coolant Loss > Page 1815 Only Be Used With Operations A Or B) 950910K Additional Time If 0.3 Hr. Equipped With A/C - Aerostar (Not To Be Used With Operation A) 95O910L Additional Time If 0.8 Hr. Equipped With A/C - Ranger, Explorer (Not To Be Used With Operation B) DEALER CODING CONDITION BASIC PART NO. CODE 6049 57 OASIS CODES: 402000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations Oil Pressure Switch: Component Locations All Except Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 1821 Limited Edition And Electronic Group Left Hand Side Of Engine, Next To Power Steering Pump Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 1822 Oil Pressure Switch: Connector Locations Left Hand Side Of Engine, Next To Power Steering Pump Oil Pressure Sending Unit Connector # C175 .............................................................................................................................................................. ....... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket Camshaft Gear/Sprocket: Service and Repair Camshaft Gear/Sprocket REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1828 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1829 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1830 Camshaft Gear/Sprocket: Service and Repair Timing Gear REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1831 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Service and Repair > Camshaft Gear/Sprocket > Page 1832 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley/Damper/Front Oil Seal Coat crankshaft damper sealing surface with clean engine oil XO-5W30-QSP (ESE-M2C153-E) or equivalent SAE 5W-30 Service SG. - Apply RTV using Rotunda RTV Dispenser 071-00001 or equivalent to keyway of damper prior to installation. CAUTION: Do not drive damper on with a hammer. - Install damper using Crankshaft Damper Replacer T74P-6316-B. - Install damper attaching bolt and tighten to 40-50 Nm (30-37 ft-lb), then turn bolt an additional 80-90 degrees tighter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket Crankshaft Gear/Sprocket: Service and Repair Crankshaft Gear/Sprocket REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1838 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1839 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1840 Crankshaft Gear/Sprocket: Service and Repair Timing Gear REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1841 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Service and Repair > Crankshaft Gear/Sprocket > Page 1842 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1846 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1847 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 17-21 Nm (13-15 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 1848 Timing Chain: Fundamentals and Basics TIMING CHAIN REPLACEMENT HINTS AND TIPS - Always replace both the timing chain and both sprockets as a combined unit. A worn timing chain will not properly fit the teeth of a new sprocket and will result in a premature failure. - A new timing chain will rapidly wear away the teeth of an old sprocket. NOTE: Since the water pump and drive belts will need to be removed during this procedure, it is important to note any related deficiencies prior to starting the procedure. - Inspect the water pump for signs of leakage and inspect the pulley for any looseness or wobble. If any wobble is detected the water pump should be replaced. - Inspect the drive belts and replace if necessary. - Inspect the drive belt idler/tensioner pulleys for looseness and wobble. Replace any pulley which does not spin freely or has any wobble. - Inspect the cooling fan clutch for proper operation. Under cold conditions the clutch should be disengaged, allowing the fan to spin freely. - Under hot conditions the clutch should tighten up, coupling the fan to the water pump pulley/shaft. - Rotate the engine to number 1 Top Dead Center prior to removing the timing chain. NOTE: The alignment marks on the camshaft and crankshaft gears are positioned at number 1 Top Dead Center. - When removing the water pump, any bolts which show signs of corrosion should be replaced and the holes/threads should be chased or re-tapped. - Oil pan removal is required to remove the timing cover. Bolts from the oil pan extend through the bottom of the timing cover. Removing the bolts and loosening the remaining pan bolts to remove the timing cover will tend to cause oil leakage from the pan gasket. NOTE: To prevent leakage, when the oil pan is removed or the bolts are loosened, the gasket should always be replaced. - When tightening the oil pan bolts always use a torque wrench. Correct sealing requires the gasket to be evenly torqued across its entire sealing surface. - Do not turn the crankshaft or camshaft with the pulleys off. Using slip joint pliers or pipe wrenches to turn the crankshaft will damage the surface and affect the press fit of the pulley. - Silicone sealant should be used very sparingly. Excessive sealant which squeezes out on the inside of the gasket can accumulate and restrict the oil pump pickup screen or the coolant heater core. - Inspect the chain guides and tensioner foot and replace if excessively worn. NOTE: If the chain guides are worn past 50% of their original thickness the guides may not last the life of the new chain and should be replaced. - When installing the chain leave the initial slack on the tensioner side, the opposite side should be tight. If any slack is left on the side opposite of the tensioner, upon initially rotating the engine the camshaft/crankshaft alignment will be incorrect. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Bolts .................................................................................................................... ................................................ 10-12 Nm (7-9 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 1852 Timing Chain Guide: Service and Repair REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 1853 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 1854 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair Timing Chain Tensioner: Service and Repair REMOVAL NOTE: It is necessary to replace the oil pan gasket when removing and installing engine front cover. It is necessary to remove the engine to remove the oil pan. 1. Remove engine front cover. 2. Push timing chain tensioner into the retracted position and install retaining clip. 3. Remove the camshaft sprocket retaining bolt and the crankshaft sprocket key. Timing Chain And Gears 4. Remove the crankshaft sprocket and camshaft sprockets with the timing chain. 5. Remove the timing chain and timing chain guide as required. INSTALLATION 1. Install the timing chain guide to the cylinder block with the pin of the guide inserted into the oil hole in the block. Install the two retaining bolts, and tighten to 10-12 Nm (7-9 ft lb). 2. Position the camshaft so the timing mark will align with the crankshaft. Position the crankshaft so the timing mark will align with the camshaft. 3. Install the crankshaft sprocket, camshaft and timing chain together. NOTE: Make sure that the tensioner side of the timing chain is held inward, and that the guide side of the chain is straight and tight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 1858 Timing Chain Alignment Marks 4. Install the crankshaft key and check the timing marks on the crankshaft sprocket and camshaft sprocket for correct alignment. 5. Install the camshaft sprocket retaining bolt, and tighten to 60-68 Nm (44-50 ft lb). 6. Remove the clip from the timing chain tensioner. 7. Check the camshaft end play. CAUTION: Prying against the camshaft gear with the valve train load on the camshaft can break or damage the gear. Therefore, the rocker arm adjusting nuts must be backed off, or the rocker arm and shaft assembly must be loosened sufficiently to free the camshaft. After checking the camshaft end play, adjust the valve clearance. Camshaft End Play a. Push camshaft toward rear of engine. Install Dial Indicator TOOL-4201-C or equivalent so indicator point is on camshaft sprocket attaching screw. b. Zero dial indicator. Pull camshaft forward and release it. Compare dial indicator reading with specifications. Camshaft end play specification is 0.0203-0.1016 mm (0.0008-0.004 in) and camshaft end play service limit is 0.2286 mm (0.009 in). If end play is excessive, replace camshaft Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Service and Repair > Page 1859 thrust plate. c. Remove dial indicator. d. After replacing thrust plate, check end play again. If it is still out of specified range, inspect camshaft and cylinder head/cylinder block for excessive wear. Engine Front Cover 8. Install the engine front cover tighten bolts to 8.5-12 Nm (6-9 ft lb). 9. Fill and bleed the cooling system. 10. Fill the crankcase with clean engine oil of the recommended grade and viscosity. 11. Start the engine and operate at fast idle. Check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Front Cover Attaching Bolts ............................................................................................................................................................. 17-21 Nm (13-15 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1863 Timing Cover: Service and Repair REMOVAL 1. Remove oil pan. 2. Drain the coolant. Remove the radiator. 3. Remove air conditioner compressor and power steering bracket, if so equipped. 4. Remove alternator and drive belt(s). 5. Remove fan. 6. Remove water pump, heater and radiator hoses. 7. Remove the drive pulley/damper assembly from the crankshaft. 8. Remove the crankshaft position sensor assembly. 9. Remove front cover retaining bolts. If necessary, tap cover lightly with a plastic hammer to break gasket seal. Remove front cover. INSTALLATION 1. Clean the front cover mating surfaces of gasket material. Apply sealing compound to the gasket surfaces on the cylinder block and back side of the front cover plate. Install guide sleeves. 2. Apply sealing compound to front cover gasket surface. Place gasket in position on front cover. Engine Front Cover 3. Place front cover on engine and start all retaining bolts two or three turns. Note the different bolt lengths. 4. Tighten front cover attaching bolts to 17-21 Nm (13-15 ft lb). 5. Install the crankshaft position sensor. 6. Install belt drive pulley/damper assembly. Tighten attaching bolt to 40-50 Nm (30-37 ft lb), then turn an additional 80-90° tighter. 7. Install oil pan. 8. Install water pump, heater hose, air conditioner compressor, alternator, and drive belt(s). Adjust drive belt tension. 9. Fill and bleed the cooling system. 10. Operate the engine at fast idle speed and check for coolant and oil leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 1869 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 1873 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 1874 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Air/fuel mixture requirement is computer controlled and not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments NOTE: Curb and fast idle speeds are controlled by the Powertrain Control Module (PCM) and Idle Air Control (IAC) valve assembly. The IAC valve and idle speed is not adjustable. A large increase or decrease in closed plate airflow from the calibrated level will not allow effective idle speed control. Throttle Body Assembly Throttle bodies with sludge tolerant design are identified with a yellow/black decal. The throttle body must not be cleaned inside the bore, as this cleaning will impair the sensitive coating. Sludge accumulation will not affect the idle air flow. The cleaning procedure for the IAC valve still applies. RPM LIMIT CHECK PROCEDURE - Self-Test constant tone STAR tester or equivalent scanner required 1. Activate engine running Self-Test. 2. After diagnostic trouble code 11 or 111 has been displayed, unlatch and within 4 seconds latch the Self-Test Input (STI) button. 3. A single pulse code indicates the entry mode, then observe the Self-Test Output (STO) of the STAR tester. - A constant tone, solid light or "STO LO" readout indicates base idle rpm is within range. - Beeping tone, flashing light, or STO LO readout at 8.0 Hz indicates Throttle Position (TP) is out of range due to over adjustment. - Beeping tone, flashing light, or STO LO readout at 4.0 Hz indicates base idle rpm is too fast. - Beeping tone, flashing light, or STO LO readout at 1.0 Hz indicates base idle is too slow. 4. To exit test, unlatch STI button, then wait 4 seconds for reinitialization (after 10 minutes it will exit by itself). 5. If the idle rpm (engine warm, in Neutral, A/C "Off") is not within limits, refer to Testing and Inspection / Procedures / Air Induction Diagnosis for other possible causes of idle problem. See: Powertrain Management/Fuel Delivery and Air Induction/Testing and Inspection/Pinpoint Tests/AIS - Air Induction Diagnosis Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Engine Water Entry Through Air Intake System Air Cleaner Fresh Air Duct/Hose: Technical Service Bulletins Engine - Water Entry Through Air Intake System Article No. 94-3-8 02/09/94 ^ AIR INTAKE - 2.9L, 3.0L, 4.0L EFI ENGINES - WATER ENTRY THROUGH AIR INTAKE SYSTEM ^ ENGINE - 2.9L, 3.0L, 4.0L EFI - POSSIBLE INTERNAL DAMAGE FROM WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK: 1986-90 BRONCO II 1986-94 RANGER 1991-94 EXPLORER This article is being republished in its entirety to add 1993-94 4.0L Ranger, 1993-94 3.0L Ranger and 1993-94 4.0L Explorer vehicles. ISSUE: Reports have been received of internal engine damage caused by water entering the engine through the air intake system. This condition may occur when the vehicle is driven in normal wet conditions, such as water splash/spray from other vehicles, or when driven through shallow water. Improvements were made to the EFI engine air intake systems that have greatly reduced the number of reported incidences. ACTION: Dealers should be assured that warranty repairs will be covered unless there Is evidence of owner misuse. This warranty repair policy will remain effective unless you are notified that a waterproof air intake system has been released. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-21-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 1886 Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL NOTE: The heat supply plenum door actuating motor and hose are not serviceable items. Repair requires the replacement of the engine air cleaner intake tube and duct. 1. Remove engine air cleaner. 2. Remove heat supply hose from exhaust manifold engine air cleaner duct shroud and tube and engine air cleaner intake tube and duct. 3. Remove one retaining screw from radiator support (baffle). 4. Remove actuator motor vacuum supply hose from bi-metal sensor in engine air cleaner assembly upper cover. 5. Remove engine air cleaner intake tube and duct from vehicle. INSTALLATION 1. Position engine air cleaner intake tube and duct and install retaining screw. 2. Reassemble engine air cleaner as described in this section. 3. Connect engine air cleaner intake tube and duct to engine air cleaner. Make sure engine air cleaner intake tube and duct snaps into place. 4. Connect vacuum hose to bi-metal sensor. 5. Install heat supply hose assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation Air Cleaner Element: Description and Operation PURPOSE Filters out unwanted dust, dirt and debris. CONSTRUCTION Chemically-treated, pleated paper element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1890 Air Cleaner Element: Service and Repair Air Intake System REMOVAL 1. Loosen outlet tube clamps from air cleaner cover and throttle body. Remove the outlet tube. 2. Disconnect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 3. Disconnect the Mass Air Flow (MAF) sensor electrical connection. 4. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 5. Remove the two air cleaner cover retaining screws, then the air cleaner cover. 6. Remove the air filter element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 1891 INSTALLATION 1. Install the air filter element. 2. Remove the air cleaner cover, then the two air cleaner cover retaining screws. Tighten the screws to 3 Nm (26 lb in). 3. Connect the IAT sensor electrical connector. 4. Connect the MAF sensor electrical connection. 5. Connect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 6. Install the outlet tube. Tighten the outlet tube clamps at the air cleaner cover and throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 1899 Spark Plug Wire Assembly Vin X V6 Firing Order: 1 4 2 5 3 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations Ignition Timing Connector: Locations Connector Location The SPOUT connector shorting bar (C107), is located at the RF corner of the engine compartment, near EDIS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation Ignition Timing Connector: Description and Operation SPOUT / SAW Connector Operation Spout/SAW Connector DESCRIPTION The Spark Angle Word (SAW),or Spark Output (SPOUT) connector is used to open and close the circuit between the Powertrain Control Module (PCM)and the Ignition Control Module (ICM) for checking base timing. OPERATION When the SPOUT or SAW connector is inserted in the harness connector, the ICM operates according to PCM timing data (computed timing). When the SPOUT or SAW connector is removed from the harness connector, the ICM operates on the Profile Ignition Pickup (PIP) signal only (base timing). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation > Page 1906 Ignition Timing Connector: Description and Operation Octane Adjustment Switch Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1913 Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1914 Ignition Cable: Description and Operation PURPOSE Conducts high voltage from the ignition coil and deliver to each spark plug in proper sequence. CONSTRUCTION Secondary ignition wires are constructed with a carbon impregnated, multi-filament synthetic fiber core. To endure under hood temperatures, the core is surrounded by heat resistant rubber insulation. Built-in internal resistance suppresses radio static and eliminates interference. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 1915 Ignition Cable: Service and Repair Spark Plug Wire Assembly REMOVAL: 1. When removing spark plug wires from the spark plugs, use the spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug insulator to free the boot. 2. Use the special tool or equivalent to pull the boot from the plug. Do not pull on the wire directly, as it may become separated from the connector inside the boot. 3. To remove the wires from the coil pack, squeeze the locking tabs of the coil wire retainer and remove using a twisting and pulling motion. Do not pull on the wire. INSTALLATION: CAUTION: Proper installation of spark plug wires is critical to vehicle operation. If one spark plug wire is not properly installed on the spark plug or ignition coil, both spark plugs connected to that coil may not fire under load. 1. Whenever a high tension wire is removed for any reason from a spark plug or ignition coil, or a new high tension wire is installed, Silicone Dielectric Compound D7AZ-19A331-A or equivalent must be applied to the boot prior to installation. Using a small tool, coat the entire interior surface of the boot. 2. Install each wire on the proper ignition coil terminal. The terminal cylinder numbers are identified on the ignition coil pack. Ensure that both coil boot retainer locking tabs have engaged. 3. Remove the wire retaining brackets from the old wiring set and install the brackets on the new wires in the same position. Install the wires and retaining brackets on the engine. 4. Connect the wires to the proper Spark plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Platinum Spark Plugs - Identification/Location Spark Plug: Technical Service Bulletins Platinum Spark Plugs - Identification/Location Article No. 94-2-8 01/26/94 ^ IGNITION SYSTEM - ELECTRONIC IGNITION (EI) PLATINUM ENHANCED SPARK PLUGS 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L ENGINES ^ ENGINE - 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L - PLATINUM ENHANCED SPARK PLUG LOCATIONS FORD: 1994 ESCORT, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Three (3) different unique styles of platinum enhanced spark plugs are produced for vehicles with Electronic Ignition (EI). Each style is distinguished by their part number suffix letters. ^ The suffix letter "P" indicates the center electrode is enhanced with platinum. ^ The suffix letter "PG" indicates the ground (side) electrode is enhanced with platinum. ^ The suffix letter "PP" indicates double platinum enhancement on both the ground (side) and center electrode. ACTION: If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter "PP" as shown on the engine decal. Refer to the following Platinum Enhanced Spark Plug Replacement Chart for correct parts usage. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000, 623000, 690000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Plug Type .......................................................... ............................................................................................................................. Motorcraft AWSF-42PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 1922 Spark Plug: Specifications Tightening Torque SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Tightening Torque ............................................. .................................................................................................................................... 7-15 ft lb (9-20 Nm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1923 Spark Plug: Description and Operation PURPOSE Spark plugs provide the path for secondary ignition system high voltage to flow to ground. OPERATION Voltage arcing between plug center and ground electrode produces the spark to ignite the air/fuel mixture. CONSTRUCTION Many spark plugs are made with an internal resistor, designed to reduce ignition system electrical interference with entertainment systems and computerized devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1924 Spark Plug: Testing and Inspection Testing For Spark 1. Remove the spark plug. 2. Connect the spark plug to the spark plug wire. 3. Hold the spark plug with insulated pliers 0.20-0.40 in (5-10 mm) from a ground. 4. Crank the engine and verify that there is a strong blue spark. If there Is no spark, replace the spark plug. Spark Plug 5. Check the following points. If a problem is found, replace the spark plug. ^ Damaged insulation ^ Worn electrodes ^ Carbon deposits. (If cleaning is necessary, use a plug cleaner or a wire brush. Clean the upper insulator also.) ^ Damaged gasket. ^ Burnt condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure ....................................................................................................................... PSI of lowest cylinder must be within 75% of highest Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Valve Arrangement (Front To Rear) ........................................................................................................................................................... L.H. I-E-I-E-I-E Valve Arrangement (Front To Rear) ........................................................................................................................................................... R.H. E-I-E-I-E-I Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 1931 Valve Clearance: Adjustments The hydraulic roller tappets have non-adjustable rocker arms. The tappets are not adjustable, and if found to be excessively worn or noisy, should be tested and replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Assembly Attaching Bolts .............................................................................................................................................. 8.5-12 Nm (6-9 ft lb) Water Pump Pulley Bolts ............................................................................................... .................................................................. 22-28 Nm (16-20 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1941 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1942 Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1943 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1944 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications COOLANT CAPACITY With A/C .............................................................................................................................................. .................................................................. 8.6 qts Without A/C ........................................................... ................................................................................................................................................ 7.8 qts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1947 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection Fan Blade: Testing and Inspection WARNING: Do not operate engine until fan has first been inspected for cracks and/or separations. If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse damaged part. Proper balance is essential in fan assembly operation. Balance cannot be ensured once a fan assembly has been found to be bent or damaged, and failure may occur during operation, creating an extremely dangerous condition. Always replace damaged fan assembly. - Place fan on flat surface with leading edge facing down. If the clearance between the fan blade touching surface and the opposite blade is more than 0.090 in (2 mm), replace the fan. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Page 1955 Fan Blade: Service and Repair 1. Remove fan clutch from water pump pulley by turning clutch assembly nut. Use fan clutch holding tool No. T84T-6312-C, or equivalent, and fan clutch nut wrench tool No. T93T-6312-B, or equivalent. 2. Remove fan shroud retaining screws. 3. Remove fan blade, fan clutch and shroud. 4. If fan blade and clutch must be separated, remove remaining bolts attaching fan blade to fan clutch. 5. Reverse procedure to install. Torque fan blade to fan clutch attaching bolts to 12-18 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation Variable Speed Fan With Coiled Bi-Metallic Thermostatic Spring PURPOSE The fan clutch causes fan speed to increase with a rise in temperature and to decrease as temperature decreases. OPERATION The fan drive clutch is a fluid coupling containing silicone oil. Fan speed is regulated by the torque-carrying capacity of the silicone oil. The more silicone oil in the coupling, the greater the fan speed, and the less silicone oil, the slower the fan speed. The fan drive clutch used is the coiled bi-metallic thermostatic spring type. The fan drive clutch uses a heat-sensitive, coiled bi-metallic spring connected to an opening plate, to control fan speed based on cooling need. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak Fan Clutch: Testing and Inspection Fan Clutch Fluid Leak Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur around the area of the bearing assembly, but if the leaks appear to be excessive, engine overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and clutch assembly by hand five times. - If no drag is felt, replace the clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1961 Fan Clutch: Testing and Inspection Fan Clutch Noise Fan clutch noise can sometimes be noticed when the clutch is engaged for maximum cooling. Clutch noise is also noticeable within the first few minutes after starting the engine while the clutch is redistributing the silicone fluid to its normal, disengaged operating condition after settling for long periods of time (over night). However, continuous fan noise or an excessive roar indicates the clutch assembly is locked-up due to internal failure. This condition can be checked by attempting to manually rotate the fan. If the fan cannot be rotated manually or there is a rough, abrasive feel as it is rotated, the clutch should be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1962 Fan Clutch: Testing and Inspection Fan Clutch Operational Test WARNING: Do not operate the engine until the fan has been first checked for possible cracks and separations. 1. Run engine at a fast idle speed 1500 RPM until normal operating temperature is reached. This can be done more quickly by blocking off the front of the radiator with cardboard. NOTE: Regardless of temperatures, the unit must be operated for at least five minutes immediately before being tested. 2. Stop engine and, using a glove or a cloth to protect the hand, immediately check the effort required to turn the fan. - If considerable effort is required, it can be assumed that the coupling is operating satisfactorily. - If very little effort is required to turn the fan, the coupling is not operating properly and should be replaced. Bi-Metallic Coiled Spring Removal 3. The clutch fan may be tested while the vehicle is being driven. To check, disconnect the bi-metallic spring, and rotate it 90° counterclockwise. This disables the temperature-controlled, free-wheeling feature and the clutch performs like a conventional fan. If this cures the overheating condition, replace the clutch fan. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 1963 Fan Clutch: Testing and Inspection Fan Looseness Lateral movement can be observed at the fan blade tip under various temperature conditions because of the type of bearing used. This movement should not exceed 1/4 in (6.5 mm) as measured at the fan tip. If this lateral movement does not exceed specifications, there is no cause for replacement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 1964 Fan Clutch: Service and Repair Removal 1. Remove the fan shroud or finger guard. CAUTION: This nut has a left-hand thread and must be rotated clockwise for removal. 2. Remove the large nut which attaches the viscous clutch to the hub of the water pump shaft using Fan Clutch Holding Tool T84T-63 12-C and Fan Clutch Nut Wrench T84T-63 1 2-D. 3. Remove the fan and clutch as an assembly. 4. Remove the bolts attaching the fan to the clutch, if necessary. Installation For installation, follow removal steps in reverse order. Tighten the fan-to-clutch bolts to 6-8 N.m (53-70 in-lb) CAUTION: This nut has left-hand thread and must be rotated counterclockwise for tightening. Tighten the fan clutch assembly nut to 40-135 N.m (30-100 ft-lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Page 1965 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 1971 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1972 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1973 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1974 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1975 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 1983 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim > Page 1988 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 1989 Heater Core: Service and Repair Removal Heater Core 1. Allow the engine to cool. Following all safety precautions and using a thick cloth, turn the radiator cap slowly to the first stop. Step back while pressure is released. When the pressure is released, tighten the radiator cap on the radiator. 2. Disconnect heater hoses from heater core tubes and plug the hoses. 3. In passenger compartment, remove four screws attaching heater core access cover to plenum assembly. Remove access cover. 4. Pull heater core rearward and down, removing it from plenum assembly. Installation 1. Position the heater core and seal in the plenum assembly. 2. Install the heater core access cover to the plenum assembly and secure it with four screws. Ensure the cover is sealed correctly before tightening the screws. 3. Install the heater hoses to the heater core tubes at the dash panel in the engine compartment. Position the hose clamps and tighten to 1.8-2.5 Nm (16-22 ilbs). 4. Check the coolant level and coolant as needed. 5. Check the system for proper operation and coolant leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate Temperature Gauge: Customer Interest Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 1999 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 2000 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate Temperature Gauge: All Technical Service Bulletins Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 2006 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 2007 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Page 2008 Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Temperature Gauge Inaccurate Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Temperature Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2011 Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2012 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Radiator - New Manufacturing Process Radiator: Technical Service Bulletins Radiator - New Manufacturing Process Article No. 95-2-4 01/30/95 COOLING SYSTEM - RADIATOR - NEW MANUFACTURING PROCESS ("CUTS" IN UPPER AND LOWER SUPPORTS) FORD: 1994 TEMPO 1994-95 ASPIRE, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1994 TOPAZ 1994-95 CONTINENTAL, COUGAR, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: A new radiator manufacturing process is currently being phased into production to provide longer radiator life. Part of the process change is to cut, lance or pierce the two (2) supports that connect the inlet and outlet tanks to relieve thermal stresses in the radiator. These cuts are located at the top and bottom of the radiator in the "U" shaped support. Refer to Figure 1. ACTION: Do not replace or return radiators because they appear to have the saw cuts in them. Those cuts are a design requirement. All cars and trucks will have saw cut radiators at some point during the 1994 and 1995 model years. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 2017 Radiator: Service and Repair REMOVAL AND INSTALLATION 1. Drain cooling system. 2. Remove rubber radiator overflow hose from radiator. 3. Remove two fan shroud attaching screws, then lift fan shroud out of lower retaining clips and drape over fan. 4. Loosen radiator upper and lower hose clamps, then remove upper and lower radiator hoses from radiator connectors. 5. On models equipped with automatic transmission, proceed as follows: a. Disconnect two transmission cooling lines from oil cooler fittings on radiator. b. Disconnect transmission cooler tube support bracket from bottom flange of radiator. 6. Remove two radiator upper attaching screws. 7. Tilt radiator back approximately one inch and lift directly upward, clear of radiator support bracket and fan blade. 8. Lift fan shroud from fan blade and remove it from vehicle. 9. Remove radiator lower support rubber insulators. 10. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Relief Pressure .................................................................................................................................... .......................................................................... 18 psi Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2027 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2028 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2029 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2030 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2031 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 2039 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge Fluctuation/Inaccurate Temperature Gauge: Customer Interest Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge Fluctuation/Inaccurate > Page 2048 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge Fluctuation/Inaccurate > Page 2049 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate Temperature Gauge: All Technical Service Bulletins Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 2055 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 2056 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Page 2057 Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Temperature Gauge Inaccurate Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Temperature Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2060 Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 2061 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics Thermostat: Technical Service Bulletins Cooling System - New System Diagnostics Article No. 93-24-8 11/24/93 ^ HESITATION - ROUGH IDLE - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE - MEDIUM TRUCKS WITH 7.0L ENGINES ^ HESITATION/STALL DURING ACCELERATION OR DECELERATION ^ IDLE - ROUGH - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE ^ HEATER/DEFROSTER - POOR HEATER OUTPUT - THERMOSTAT STUCK OPEN ^ COOLING SYSTEM - NEW DIAGNOSTICS FOR ENGINES THAT DO NOT REACH NORMAL OPERATING TEMPERATURE FORD: 1983-94 ESCORT 1984-87 EXP 1984-94 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1985-90 BRONCO II 1986-94 AEROSTAR 1988-94 F SUPER DUTY 1991-94 EXPLORER This TSB article is being republished in its entirety to include 1994 model year vehicles. ISSUE: Engine performance concerns such as hesitation or stall, rough idle, and/or poor fuel economy may be caused by the thermostat stuck in an open position or opening at a temperature lower than specified. ACTION: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2066 Use the following "Cooling System Diagnosis" procedure to diagnose a cooling system that may not be reaching normal operating temperature. Follow the "Thermostat Diagnosis" procedure to determine if the thermostat may be at fault. Check the thermostat without removing it from the vehicle by using Rotunda Service Coolant Temperature Monitor Harness 007-00064. A new cooling system diagnosis procedure has been developed for engines that do not reach normal operating temperature. A new thermostat diagnosis procedure also has been developed, using a new service coolant temperature monitor harness. NOTE: THIS PROCEDURE WILL DIAGNOSE ONLY COOLING SYSTEMS THAT MAY NOT BE REACHING NORMAL OPERATING TEMPERATURE. IT WILL NOT DIAGNOSE A THERMOSTAT THAT CAUSES AN ENGINE OVERHEAT CONDITION. NOTE: THE ESCORT/TRACER SPECIFIC APPLICATION FOR THIS ARTICLE IS AS FOLLOWS: ^ 1983-1990 Escort 1.9L and 1.6L ^ 1991-1994 Escort 1.9L ^ 1991-1994 Tracer 1.9L Only THERMOSTAT DIAGNOSIS NOTE: DISCONNECTING THE POWERTRAIN CONTROL MODULE (PCM) TO ATTACH A BREAKOUT BOX OR AN EEC IV MONITOR WILL ERASE THE ADAPTIVE LEARNING FROM MEMORY AND MAY "HIDE" A DRIVE CONCERN TEMPORARILY UNTIL THE ADAPTIVE LEARNING IS RE-LEARNED. NOTE: THIS PROCEDURE IS MOST ACCURATE IF PERFORMED INDOORS AT LESS THAN 100~F (38~C) AMBIENT TEMPERATURE. THIS TEST MAY BE PERFORMED WITH OR WITHOUT THE HOOD OPEN AND WITH THE ENGINE WARM OR COLD. CAUTION: ALWAYS VENT THE EXHAUST TO THE OUTSIDE WHEN PERFORMING THIS TEST. 1. Check the coolant level in the radiator and coolant recovery reservoir. 2. With the key in the "off" position, proceed as follows: a. Remove the engine coolant temperature (ECT) sensor harness connector. b. Attach Rotunda Service Coolant Temperature Monitor Harness 007-00064 as a jumper between the PCM and the ECT. c. Attach Rotunda 73 Digital Multimeter 105-00051 or equivalent to the thermostat monitor harness. Voltage values (0-5vdc) may now be Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2067 monitored while the sensor retains its connection to the wiring harness. NOTE: A ROTUNDA NEW GENERATION STAR TESTER (NGS) 007-00500 OR THE ROTUNDA SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) 001-00001 MAY BE USED TO MONITOR THE ECT ON VEHICLES EQUIPPED WITH DATA COMMUNICATIONS LINK (DCL). THE SBDS SEQUENCE TO USE FOR THE SCREEN IS "TOOLBOX - ELECTRONIC ENGINE CONTROL AND DCL - ITEM". 3. Vehicles equipped with electric engine cooling fan(s) must have a fan running during this test (high or low speed may be used). Two methods may be used to turn the fan(s) on: a. Disconnect the A/C compressor clutch power supply and turn the climate control to A/C "ON". Or b. Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector from the battery. NOTE: A GROUND MAY BE REQUIRED FOR SOME APPLICATIONS. 4. Place transmission in "park" or "neutral". NOTE: RUNNING THIS TEST WITH THE VEHICLE IN GEAR OR WITH THE A/C COMPRESSOR CLUTCH ENGAGED (RUNNING) WILL CAUSE IMPROPER DIAGNOSIS 5. Start the engine and allow to idle throughout this test: a. Allow engine to run for 2 minutes, then record ECT voltage. b. From now on, record ECT voltage every 60 seconds. c. When the ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. d. Use the "Voltage and Corresponding Temperature Chart" shown to obtain actual coolant temperatures. 6. If the opening voltage is GREATER than 0.75 volts (less than 18~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, replace the thermostat. Refer to the dealer Master Parts Catalog for correct thermostat usage. 7. If the thermostat opening voltage is LESS than 0.75 volts (greater than 180~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, the thermostat is good and should NOT be replaced. The "Cooling System Diagnosis Chart" should be referenced for further instructions. NOTE: The 10~ F opening temperature difference for the 2.3L HSC engine is due to the ECT sensor location. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-14-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 402000, 608000, 608400, 609000, 609400, 611000, 611500, 622000, 690000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test Thermostat: Testing and Inspection Thermostat Test The thermostat should be replaced only after the following tests have been performed: 1. Heat Test 89° C (192° F) Thermostat Immerse the removed thermostat in a 89°C (192°F) solution of antifreeze and water mixture. An 89°C (192°F) thermostat should open to 0.08 mm (0.0003 inch). When immersed in a 100° C (212° F) solution, the thermostat should open to 3.2 mm (1/8 inch). 92° C (197° F) Thermostat A 92°C (197°F) thermostat immersed in a 92°C (197°F) solution of antifreeze and water should open to O.O8 mm (0.0003 inch), when immersed in the 100° C (212° F) solution, the thermostat should open 3.2 mm (1/8 inch). 2. Visual Test a. If heat is not available, the thermostat should be checked for leakage. This is done by holding the thermostat up to a lighted background. Leakage of light around the thermostat valve (thermostat at room temperature) indicates that the thermostat should be replaced with an original equipment, approved thermostat. Some thermostats have a small leakage notch at one location on the perimeter of the thermostat valve which is considered normal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test > Page 2070 Thermostat: Testing and Inspection Electrical Thermostat Test CAUTION: Always vent the exhaust to the outside when performing this test. NOTE: Procedure is most accurate if performed indoors at less than 37.8° C (100° F) ambient air. This test may be performed with or without the hood open and with the engine warm. 1. Check coolant level in radiator and engine coolant recovery reservoir. Fill as needed. 2. With the key OFF, remove the Engine Coolant Temperature ECT sensor harness connector and attach the Rotunda Service Coolant Temperature Monitor Harness 007-00064 or equivalent as a jumper between the Powertrain Control Module PCM and the ECT. Attach a Rotunda 73 Digital Multimeter 1005-R0051 or equivalent to the thermostat monitor harness. Voltage values (0 to 5 V) may now be monitored while the sensor retains its connection to the wiring harness. 3. Place transmission in PARK (P) or NEUTRAL (N). NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause improper diagnosis. 4. Start the engine and allow it to idle throughout this test. Allow engine to run for 2 minutes, then record the ECT voltage. Record ECT voltage every 60 seconds. When ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and temperature chart that follows: Coolant Temperature .................................................................. ............................................................................................................ ECT Volts 22° C (71° F) ....................................................................................................................................... .................................................. 3.00 volts 43° C (109° F) .................................................................. ..................................................................................................................... 2.01 volts 71° C (159° F) .............................................................................................................................................................. ......................... 1.01 volts 82° C (180° F) ........................................................................................... ............................................................................................ 0.75 volts 91° C (195° F) ........................ .............................................................................................................................................................. . 0.59 volts 97° C (206° F) ................................................................................................................... .................................................................... 0.50 volts 105° C (221° F) ................................................................................................................................... .................................................... 0.40 volts 5. If the thermostat opening voltage is greater than 0.75 volts and less than 82° C (180° F), replace the water thermostat. 6. If the thermostat opening voltage is less than 0.75 volts and greater than 82° C (180° F), water thermostat is good and should not be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Page 2071 Thermostat: Service and Repair REMOVAL CAUTION: Do not pry on water thermostat to remove. 1. Drain the cooling system so that the coolant level is below the water thermostat. 2. Remove the coolant outlet housing retaining bolts. Pull the elbow away from the intake manifold sufficiently to provide access to the water thermostat. Remove the water thermostat and gasket. INSTALLATION WARNING: Do not stand in line with or near radiator fan blade when engine is running. WARNING: To prevent incorrect installation of the water thermostat, the water outlet connection casting contains a locking recess into which the water thermostat is turned and locked. Install the water thermostat with the bridge section in the outlet casting. Turn the water thermostat clockwise to lock it in position on the flats cast into the water outlet connection. 1. Clean the coolant water outlet connection. Coat a new gasket with Perfect Seal Sealing Compound B5A-19554-A (ESR-M18PZ-A) or equivalent. Position the gasket on the intake manifold opening. NOTE: It is critical that the correct water thermostat installation alignment be made to provide coolant flow to heater. Insert and rotate water thermostat to the left or right until it stops in the water outlet connection housing, then visually check for full width of heater outlet tube opening to be visible within the thermostat port in assembly. This port alignment at assembly is required to provide maximum coolant flow to the heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Page 2072 2. Position the coolant water outlet connection against the intake manifold. Install and tighten the retaining bolts to 9-12 Nm (80-106 in lb). 3. Fill the cooling system with the recommended Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A) or equivalent and water mixture. Check for leaks and proper coolant level after the engine has reached operating temperature. NOTE: A coolant mixture of 50 percent coolant concentrate and 50 percent water is recommended to maintain best overall performance. To avoid damaging the radiator, the coolant concentrate should not exceed 60 percent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications Thermostat Housing Retaining Bolts ............................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 2076 Thermostat Housing: Service and Repair REMOVAL CAUTION: Do not pry on water thermostat to remove. 1. Drain the cooling system so that the coolant level is below the water thermostat. 2. Remove the coolant outlet housing retaining bolts. Pull the elbow away from the intake manifold sufficiently to provide access to the water thermostat. Remove the water thermostat and gasket. INSTALLATION WARNING: Do not stand in line with or near radiator fan blade when engine is running. WARNING: To prevent incorrect installation of the water thermostat, the water outlet connection casting contains a locking recess into which the water thermostat is turned and locked. Install the water thermostat with the bridge section in the outlet casting. Turn the water thermostat clockwise to lock it in position on the flats cast into the water outlet connection. 1. Clean the coolant water outlet connection. Coat a new gasket with Perfect Seal Sealing Compound B5A-19554-A (ESR-M18PZ-A) or equivalent. Position the gasket on the intake manifold opening. NOTE: It is critical that the correct water thermostat installation alignment be made to provide coolant flow to heater. Insert and rotate water thermostat to the left or right until it stops in the water outlet connection housing, then visually check for full width of heater outlet tube opening to be visible within the thermostat port in assembly. This port alignment at assembly is required to provide maximum coolant flow to the heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications > Page 2077 2. Position the coolant water outlet connection against the intake manifold. Install and tighten the retaining bolts to 9-12 Nm (80-106 in lb). 3. Fill the cooling system with the recommended Premium Cooling System Fluid E2FZ-19549-AA (ESE-M97B44-A) or equivalent and water mixture. Check for leaks and proper coolant level after the engine has reached operating temperature. NOTE: A coolant mixture of 50 percent coolant concentrate and 50 percent water is recommended to maintain best overall performance. To avoid damaging the radiator, the coolant concentrate should not exceed 60 percent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Assembly Attaching Bolts .............................................................................................................................................. 8.5-12 Nm (6-9 ft lb) Water Pump Pulley Bolts ............................................................................................... .................................................................. 22-28 Nm (16-20 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2092 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2093 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2099 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2100 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 2101 Catalyst Shield: Testing and Inspection NOTE: At idle or during normal driving conditions, a buzz or rattle may be detected, which can be traced to the exhaust system. The heat shield attachment to the muffler or catalytic converter may come free. The loose shield will vibrate off the muffler or catalytic converter and cause the buzz or rattle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 2102 Catalyst Shield: Service and Repair Catalyst Heat Shields NOTE: The catalytic converter may have two cans. If shields on both cans are loose, four clamps (two for each) will be required. ^ Attach two band clamps to the catalytic converter or muffler as shown. Tighten to 7 Nm (60 in lb). ^ Align the clamp to secure the heat shield to the muffler or catalytic converter. Tighten the clamp to no more than 7 Nm (60 in lb). ^ Trim excess "ear" to approximately 25mm (1 inch). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair Exhaust Manifold: Service and Repair REMOVAL AND INSTALLATION 1. If removing left exhaust manifold, remove oil level indicator tube support bracket, then power steering pump pressure and return hoses if necessary. 2. If removing right exhaust manifold, remove heater hose support bracket, then disconnect heater hoses. 3. Remove manifold to exhaust pipe nuts, then exhaust manifold bolts and manifold. 4. Reverse procedure to install. NOTE: Lightly oil all bolt and stud threads before installation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 96417 > Feb > 96 > Engine Mount/Muffler Vibration/Shake While Driving Exhaust Pipe: Customer Interest Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 96417 > Feb > 96 > Engine Mount/Muffler Vibration/Shake While Driving > Page 2114 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration Exhaust Pipe: Customer Interest Exhaust System - Whistle Noise On Acceleration Article No. 94-23-17 11/14/94 ^ EXHAUST SYSTEM - "WHISTLE" NOISE ON ACCELERATION - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 ^ NOISE - "WHISTLE" ON ACCELERATION FROM EXHAUST SYSTEM - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may exhibit a high pitched "whistle" noise coming from the exhaust once the vehicle is warmed up. This may be caused by a weld skip on the internals of the muffler. As the vehicle warms up, the weld skip opens up and allows air to travel through at high speeds resulting in the whistle. ACTION: Replace the muffler and tailpipe assembly with a new assembly built outside of the build dates listed. The new assemblies will not have the weld skip. Refer to the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle by the frame allowing the rear suspension to hang freely. 2. Remove the muffler and tailpipe assembly. a. Remove the spring bolt assemblies. b. Unhook the tailpipe from the rear hanger insulator. c. Unhook the muffler body from the hanger insulator. d. Remove the muffler and tailpipe assembly. 3. Inspect the inlet gasket and reuse if it is not damaged. Replace if necessary. 4. Install the correct muffler and tailpipe assembly. a. Install the muffler hanger to insulator. b. Install the tailpipe hanger to insulator. c. Install the spring bolt assemblies. d. Inspect the exhaust system for proper alignment and for possible contact with any part of the vehicle. Adjust as necessary. e. Torque spring bolts to 25-35 N-m (18-26 lb.ft.). 5. Start the engine and check for leaks. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Pipe: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration > Page 2119 Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942317A Replace Muffler Assembly 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 5230 56 OASIS CODES: 403000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 96417 > Feb > 96 > Engine Mount/Muffler Vibration/Shake While Driving Exhaust Pipe: All Technical Service Bulletins Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 96417 > Feb > 96 > Engine Mount/Muffler Vibration/Shake While Driving > Page 2125 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 942317 > Nov > 94 > Exhaust System Whistle Noise On Acceleration Exhaust Pipe: All Technical Service Bulletins Exhaust System - Whistle Noise On Acceleration Article No. 94-23-17 11/14/94 ^ EXHAUST SYSTEM - "WHISTLE" NOISE ON ACCELERATION - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 ^ NOISE - "WHISTLE" ON ACCELERATION FROM EXHAUST SYSTEM - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may exhibit a high pitched "whistle" noise coming from the exhaust once the vehicle is warmed up. This may be caused by a weld skip on the internals of the muffler. As the vehicle warms up, the weld skip opens up and allows air to travel through at high speeds resulting in the whistle. ACTION: Replace the muffler and tailpipe assembly with a new assembly built outside of the build dates listed. The new assemblies will not have the weld skip. Refer to the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle by the frame allowing the rear suspension to hang freely. 2. Remove the muffler and tailpipe assembly. a. Remove the spring bolt assemblies. b. Unhook the tailpipe from the rear hanger insulator. c. Unhook the muffler body from the hanger insulator. d. Remove the muffler and tailpipe assembly. 3. Inspect the inlet gasket and reuse if it is not damaged. Replace if necessary. 4. Install the correct muffler and tailpipe assembly. a. Install the muffler hanger to insulator. b. Install the tailpipe hanger to insulator. c. Install the spring bolt assemblies. d. Inspect the exhaust system for proper alignment and for possible contact with any part of the vehicle. Adjust as necessary. e. Torque spring bolts to 25-35 N-m (18-26 lb.ft.). 5. Start the engine and check for leaks. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Pipe: > 942317 > Nov > 94 > Exhaust System Whistle Noise On Acceleration > Page 2130 Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942317A Replace Muffler Assembly 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 5230 56 OASIS CODES: 403000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise Heat Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 2139 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System Buzzing/Rattling Noise > Page 2140 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Heat Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2146 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heat Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 2147 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving Muffler: Customer Interest Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving > Page 2156 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration Muffler: Customer Interest Exhaust System - Whistle Noise On Acceleration Article No. 94-23-17 11/14/94 ^ EXHAUST SYSTEM - "WHISTLE" NOISE ON ACCELERATION - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 ^ NOISE - "WHISTLE" ON ACCELERATION FROM EXHAUST SYSTEM - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may exhibit a high pitched "whistle" noise coming from the exhaust once the vehicle is warmed up. This may be caused by a weld skip on the internals of the muffler. As the vehicle warms up, the weld skip opens up and allows air to travel through at high speeds resulting in the whistle. ACTION: Replace the muffler and tailpipe assembly with a new assembly built outside of the build dates listed. The new assemblies will not have the weld skip. Refer to the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle by the frame allowing the rear suspension to hang freely. 2. Remove the muffler and tailpipe assembly. a. Remove the spring bolt assemblies. b. Unhook the tailpipe from the rear hanger insulator. c. Unhook the muffler body from the hanger insulator. d. Remove the muffler and tailpipe assembly. 3. Inspect the inlet gasket and reuse if it is not damaged. Replace if necessary. 4. Install the correct muffler and tailpipe assembly. a. Install the muffler hanger to insulator. b. Install the tailpipe hanger to insulator. c. Install the spring bolt assemblies. d. Inspect the exhaust system for proper alignment and for possible contact with any part of the vehicle. Adjust as necessary. e. Torque spring bolts to 25-35 N-m (18-26 lb.ft.). 5. Start the engine and check for leaks. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Customer Interest: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration > Page 2161 Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942317A Replace Muffler Assembly 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 5230 56 OASIS CODES: 403000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving Muffler: All Technical Service Bulletins Engine Mount/Muffler - Vibration/Shake While Driving Article No. 96-4-17 02/12/96 ^ VIBRATION - "AFTERSHAKE" - LESS THAN 72 KM/H (45 MPH) WHEN DRIVING OVER A BUMP - 2-DOOR - WITHOUT ENGINE BLOCK HEATER ^ VIBRATION - SHAKE - ABOVE 80 KM/H (50 MPH) - ALL DRIVING MODES - SMOOTH ROAD OPERATION - 2-DOOR - WITHOUT ENGINE BLOCK HEATER LIGHT TRUCK: 1991-94 EXPLORER This TSB article is being republished in its entirety to delete a Policy Manual reference. ISSUE: A vibration/shake may be felt in the seat and/or floor at speeds above 80 km/h (50 mph) and peaking near 105 km/h (65 mph) on some vehicles. This condition is not rpm dependent and occurs in all driving modes, i.e., acceleration, cruise and deceleration. An "aftershake" condition may also exist when driving over a bump at speeds less than 72 km/h (45 mph). This condition may improve with tire balancing or tire exchange, but may not be completely eliminated. This may be the result of the movement frequency of the engine aligning with the tire rotation frequency, causing the vibration/shake. ACTION: Confirm the vibration/shake condition occurs in all driving modes, including neutral coast. Install revised LH and RH engine mounts and a rear axle-to-frame lateral shock absorber kit. Also, install a revised muffler tailpipe assembly on all 1991-94 model years. Refer to the following Service Procedure for details. This procedure will NOT compensate for: ^ Out-of-round or out-of-balance tire/wheel assemblies ^ Vibration resulting from abnormal tire wear ^ Other tire/wheel quality or out-of-specification issues. Wheel/tire assemblies may require service if the vehicle is not acceptable following the new engine mount and rear axle shock absorber installation. Refer to the Noise/Vibration/Harshness (NVH) Section of the appropriate Explorer Service Manual for further details. NOTE: THIS TSB ARTICLE DOES NOT APPLY TO VEHICLES WITH ENGINE BLOCK HEATERS. INADEQUATE CLEARANCE EXISTS FOR NEW ENGINE MOUNT INSTALLATION WHEN THE VEHICLE IS EQUIPPED WITH AN ENGINE BLOCK HEATER. SERVICE PROCEDURE 1. Visually inspect the tires for abnormal/irregular wear patterns. If necessary, replace the tire(s) with original equipment type and size. Set tire pressure as specified on the certification label located on the left front door pillar. 2. Check the tire/wheel assembly for correct balance and repair as necessary. 3. If the vibration/shake condition still exists, install the new Engine Mount and Rear Axle Shock Absorber Kit (F67Z-6K007-AA) as per TSB Article 96-4-15. Refer to the Instruction Sheets included with the kit for service details. NOTE: REPLACE EXHAUST SYSTEM ON ALL VEHICLES WITH OR WITHOUT A RESONATOR. 4. Use the following service repair procedure for replacing the muffler tailpipe assembly: a. Hoist vehicle and remove the right rear tire/wheel assembly. b. Remove muffler-to-catalyst attachment bolts. c. Remove tailpipe hanger rod from insulator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 96417 > Feb > 96 > Engine Mount/Muffler - Vibration/Shake While Driving > Page 2167 d. Remove muffler body hanger rods from insulators. e. Remove muffler tailpipe assembly from vehicle. f. Remove and replace gasket (E9TZ-5E241-A). g. Install new muffler tailpipe assembly (F67A-5230-BEA). h. Insert muffler body hanger rods into insulators. Insert tailpipe hanger rods into insulators. j. Assemble muffler-to-catalyst torquing bolts to 40 N-m (30 lb-ft). k. Lower vehicle on hoist. PART NUMBER PART NAME F67Z-6K007-AA Engine Mount And Rear Axle Shock Absorber Kit E9TZ-5E241-A Gasket F67Z-5230-BEA Muffler Tailpipe Assembly OTHER APPLICABLE ARTICLES: 96-4-15 SUPERSEDES: 96-1-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For 1991 Model Year Vehicles OPERATION DESCRIPTION TIME 960417A Replace Engine Mount 3.4 Hrs. Assemblies, Install Rear Axle Lateral Shock Absorber And Replace Muffler Assembly DEALER CODING CONDITION BASIC PART NO. CODE 6K007 79 OASIS CODES: 703000, 703200, 703300, 703400 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration Muffler: All Technical Service Bulletins Exhaust System - Whistle Noise On Acceleration Article No. 94-23-17 11/14/94 ^ EXHAUST SYSTEM - "WHISTLE" NOISE ON ACCELERATION - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 ^ NOISE - "WHISTLE" ON ACCELERATION FROM EXHAUST SYSTEM - VEHICLES WITH 4.0L ENGINES BUILT 12/7/93 THROUGH 12/31/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may exhibit a high pitched "whistle" noise coming from the exhaust once the vehicle is warmed up. This may be caused by a weld skip on the internals of the muffler. As the vehicle warms up, the weld skip opens up and allows air to travel through at high speeds resulting in the whistle. ACTION: Replace the muffler and tailpipe assembly with a new assembly built outside of the build dates listed. The new assemblies will not have the weld skip. Refer to the following service procedure. SERVICE PROCEDURE 1. Raise the vehicle by the frame allowing the rear suspension to hang freely. 2. Remove the muffler and tailpipe assembly. a. Remove the spring bolt assemblies. b. Unhook the tailpipe from the rear hanger insulator. c. Unhook the muffler body from the hanger insulator. d. Remove the muffler and tailpipe assembly. 3. Inspect the inlet gasket and reuse if it is not damaged. Replace if necessary. 4. Install the correct muffler and tailpipe assembly. a. Install the muffler hanger to insulator. b. Install the tailpipe hanger to insulator. c. Install the spring bolt assemblies. d. Inspect the exhaust system for proper alignment and for possible contact with any part of the vehicle. Adjust as necessary. e. Torque spring bolts to 25-35 N-m (18-26 lb.ft.). 5. Start the engine and check for leaks. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 942317 > Nov > 94 > Exhaust System - Whistle Noise On Acceleration > Page 2172 Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 942317A Replace Muffler Assembly 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 5230 56 OASIS CODES: 403000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Muffler: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Compass: All Technical Service Bulletins Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Component Locations The Powertrain Control Module (PCM) is located under dash, at RH kick panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Diagrams Connector Views Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2191 PCM Connector View Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2192 Powertrain Control Module: Diagrams Terminal Identification Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2193 Powertrain Control Module: Description and Operation PURPOSE The Powertrain Control Module (PCM) monitors the signals from various input sensors and calculates the proper operating strategy for the engine operating conditions. In addition to normal operating strategy the PCM calculates/learns an adaptive strategy that compensates for normal wearing and aging of components. The PCM also provides for self-diagnostic testing. When the ignition is turned on the PCM is continuously checking its inputs and outputs for values out of specification. Any discrepancies are recorded as diagnostic trouble codes. The PCM also provides for operator initiated self-tests. These tests check for specific input values and output states under defined conditions. Note: Incorrect testing conditions and minor procedural deviations often result in false trouble codes and inaccurate information. When initiating self-tests technicians should verify that all required conditions are met. OPERATION The PCM continuously monitors input signals and compares these values to calibration information stored in its memory. The PCM's calibration assembly contains the necessary programming to fine-tune the PCM's engine calibration commands to the vehicle's weight, axle ratio, and transmission application. The calibration assembly is an integral part of the PCM and is not replaceable. The PCM determines the correct operating strategy and makes the necessary corrections to its output signals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure Powertrain Control Module: Reset Procedure KEEP ALIVE MEMORY AND ADAPTIVE STRATEGY The EEC-IV system constantly monitors and adjusts the PCM calibration to correct for normal wear and aging of components. The PCM uses these calibration adjustments to shift fuel delivery calculations and idle speed specifications to compensate for the aging of the vehicle. When an Electronic Engine Controls (EEC) system component is replaced, the Keep Alive Memory (KAM) should be cleared to erase the information stored by the processor from the original component. CLEARING KEEP ALIVE MEMORY To clear the KAM, disconnect the battery negative terminal for five minutes or more (preferably 15 minutes). ADAPTIVE STRATEGY RELEARN PROCEDURE After repairs have been made and the KAM cleared drive the the vehicle for at least ten miles to allow the PCM to relearn the values for optimum performance. NOTE: During the ten mile relearn drive, the vehicle may exhibit some driveability symptoms. These should be eliminated when the KAM has relearned the operating values. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure > Page 2196 Powertrain Control Module: Removal and Replacement Powertrain Control Module NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REMOVAL 1. Open hood and disconnect negative battery cable. 2. Remove two screws and right cowl side panel. 3. Disconnect PCM electrical connector. 4. Remove three screws and PCM bracket. 5. Disconnect PCM from connector and remove. INSTALLATION To install PCM, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2200 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2201 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Box The Fuel Pump Relay is located in the power distribution box, on the right side of the engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2213 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2214 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2215 Fuel Pump Relay: Description and Operation OPERATION When the ignition switch is turned ON, the Electronic Engine Control (EEC) power relay is energized, providing power to the fuel pump relay for 1 to 2 seconds through the Powertrain Control Module (PCM) and an Inertia Fuel Shutoff (IFS) switch. Fuel pump power is provided through the fuel pump relay contacts, if the PCM does not receive an ignition signal within approximately one second after the ignition switch is turned to the "ON" position. A timer circuit in the PCM will open the ground circuit to the fuel pump relay, causing the fuel pump relay contacts to OPEN. This action stops the power supply to the fuel pump. When the ignition switch is turned to the "START" position, the PCM closes the ground circuit to the fuel pump relay, resuming operation of the fuel pump. After the ignition switch is returned to the "ON" position, power to the fuel pump is supplied through the fuel pump relay. The PCM monitors engine speed and opens the fuel pump relay ground circuit if the engine speed drops below 120 rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2219 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2220 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Ignition Control Module: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 2226 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 2227 Ignition Control Module: Technical Service Bulletins Ignition Control Module - Connector Update Article No. 94-7-8 WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR - FORMERLY CALLED ELECTRONIC DISTRIBUTORLESS IGNITION SYSTEM (EDIS) CONNECTOR - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, GRAND MARQUIS, MARK VIII, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Beginning 1/3/94 revised design ICM connectors are being used after the old style connectors are exhausted. The revised connector has a new seal and new design for better retention. Although the connectors are interchangeable, they pull apart differently. ACTION: If service is required, be aware of the new design when taking the ICM connector apart. ^ The previous style connector had a split beam that had to be pushed "down" while the connector was being pulled off. The word "PUSH" is embossed on the end of the split beam, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 2228 ^ The revised style connector has a beam (not split) that must be pried "up", and then pulled off, Figure 2. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2229 Ignition Control Module: Specifications TIGHTENING SPECIFICATIONS ICM mounting screw ............................................................................................................................ ................................... 27-35 lb. in. (3-4 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2230 Ignition Control Module: Locations IGNITION CONTROL MODULE (ICM) LOCATION On RH front corner of engine compartment, left of headlamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2231 Ignition Control Module (ICM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2232 Ignition Control Module: Description and Operation EDIS Module PURPOSE The Electronic Distributorless Ignition System (EI), formerly (EDIS)module's primary function is to deliver full energy spark at a crank angle targeted by the Powertrain Control Module (PCM) and to provide the PCM with crankshaft position information. DESCRIPTION The EI control module is a twelve pin custom microprocessor-based thick film module. Although each engine is very different in size and structure, ICM's for each engine are very similar. With the exception of some pin assignments, basic operation of the EI systems for the different engines is identical. OPERATION The EI control module (ICM) receives input from the Variable Reluctance Sensor (VRS) style Crankshaft Position (CKP) Sensor in order to identify the passing of the missing tooth on the VRS trigger wheel. Synchronization The module is said to be "synchronized" when the missing tooth is found. Synchronization is essential to the ICM in order to track the angular position of the crankshaft relative to a fixed reference and when it should fire the proper coil. Profile Ignition Pickup Profile Ignition Pickup (PIP) output is synthesized by the ICM using input from the VRS signal. The PIP signal generated by the ICM indicates engine speed and crankshaft position to the PCM. The PIP signal is used by the PCM so that it can enable fuel and spark functions and generate a Spark Angle Word (SAW) signal. Spark Angle Word The SAW signal provides spark targeting information to the ICM. By decoding the SAW signal and using the information it receives from the VRS, the ICM turns the coils on and off at correct times and in proper sequence. The EI system operates at a high data rate so it can fire sparks more accurately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 2233 Ignition Control Module: Service and Repair Ignition Module REMOVAL 1. Disconnect both battery cables, then remove the battery from the vehicle. 2. Disconnect the electrical connector from the ignition module. NOTE: To disconnect the module connector, push on the connector where it says PUSH, then slide the connector from the module. 3. Remove the ignition module retaining bolt and remove the module by sliding the assembly up until it is released from the teardrop shaped hole in the sheet metal. INSTALLATION 1. Place the module on the sheet metal so the retaining rivet passes through the hole, then slide the module down into position. 2. Install the retaining bolt bolt, torquing to 22-31 lb-in (2.2-3.5 Nm). 3. Connect the electrical connector to the module. 4. Install the battery and cables. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2244 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2245 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2251 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2252 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2257 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2263 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 2266 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2267 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2268 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2269 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2270 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2276 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2277 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2278 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2279 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2280 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2281 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions Clutch Pedal Position Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2286 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2287 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2288 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2289 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2290 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2291 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2292 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2293 Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2294 Neutral Drive Input Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Page 2295 Clutch Pedal Position Switch: Description and Operation PURPOSE The Clutch Pedal Position (CPP) switch provides an input to the Powertrain Control Module (PCM), allowing it to compensate for changes in engine load resulting from clutch operation. The PCM adjusts the idle speed and air/fuel ratio according to input from the CPP switch. OPERATION A 5.0 volt reference signal is applied to the CPP from the PCM. The CPP switch is open with the clutch pedal up and closed when down. When the switch is closed it applies ground, through the signal return circuit, to the CPP circuit, informing the PCM that the clutch pedal is depressed. RELATED DIAGNOSTIC TROUBLE CODES DTC 528 - CPP circuit failure, during Key On Engine OFF (KOEO) self-test or while cranking the PCM sensed a high voltage (clutch pedal not depressed) on the CPP circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2300 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2301 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2302 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2303 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2304 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2309 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2310 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2313 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2314 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2315 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2316 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2317 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2318 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2319 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2320 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2321 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2322 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2323 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations Cylinder Identification Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Cylinder Identification Sensor (CID), or Camshaft Position Sensor (CMP) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations > Page 2327 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal Cylinder Identification Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2330 Cylinder Identification Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2331 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2332 Cylinder Identification Sensor: Testing and Inspection Refer to Computers and Controls: System Diagnosis: Flow of Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2333 Cylinder Identification Sensor: Service and Repair For California, Sequential Fuel Injected (SFI) Models Only REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2334 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2335 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2336 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications Intake Air Temperature Sensor: Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values Notes: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Ambient temperature should be above 10°C (50°F) to receive acceptable input from the Intake Air Temperature (IAT) sensor. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications > Page 2341 Intake Air Temperature Sensor: Mechanical Specifications TORQUE SPECIFICATION Intake air temperature sensor ......................................................................................................................................................... 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2342 Intake Air Temperature Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2343 Intake Air Temperature Sensor: Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2344 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the incoming air flow. The Powertrain Control Module (PCM) uses this information to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The IAT is a two lead thermistor type sensor with a negative temperature coefficient and is located in the intake air flow path. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the IAT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the incoming air increases the resistance of the IAT decreases and the voltage drop across the IAT decreases. A decrease in air temperature will increase the resistance of the IAT and raise the voltage drop across the sensor. The normal operating range of the IAT is 3.50 volts (50°F) to 1.02 volts (158°F). Note: Due to its negative temperature coefficient minor increases in resistance across the IAT circuit harness and ground connections can result in temperature values that are much lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 64/112 - The IAT sensor output is less than the self-test minimum, 0.2 volts. DTC 54/113 - The IAT sensor output is greater than the self-test maximum, 4.6 volts. DTC 24/114 - The IAT sensor output is out of self-test range, 0.3-3.7 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2345 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect electrical connector from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from intake manifold. INSTALLATION 1. To install, reverse removal procedure. 2. Tighten IAT sensor to 8-13 Nm (6-8 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. 3. Connect negative battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Heated Oxygen (HO2S) Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2350 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2351 Heated Oxygen (HO2S) Sensor: Technical Service Bulletins Heated Exhaust Gas Oxygen Sensor Application Chart Article No. 94-16-9 08/10/94 EXHAUST - HEATED OXYGEN SENSOR (H02S) - APPLICATION CHART FORD: 1991-94 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1991-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1993-94 MARK VIII LIGHT TRUCK: 1991-94 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER MEDIUM/HEAVY TRUCK: 1991 F & B SERIES ISSUE: Quick Reference Heated Oxygen Sensor (H02S) Application Charts have been developed to assist technicians and parts managers in correct parts usage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2352 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2353 ACTION: Refer to the appropriate Quick Reference Heated Oxygen Sensor (HO2S) Application Chart for Passenger Car or Truck, Figures 1 and 2, to make sure that the correct service sensor is installed. In some cases, new applications are shown. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2354 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications Heated Oxygen (HO2S) Sensor: Electrical Specifications HEATER ELEMENT RESISTANCE Hot to warm ......................................................................................................................................... .................................................. 5.0-30.0 ohms Room temperature .................................................... ............................................................................................................................... 2.0-5.0 ohms HO2S SWITCHING HO2S signal ........................................................................................................................................ .......................... 0.3-0.9 volts within 3 seconds After driving 55 mph for 5 minutes. Testing procedures may be found under System Testing / Pinpoint tests. See: Computers and Control Systems/Testing and Inspection/Pinpoint Tests/H - Fuel Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications > Page 2357 Heated Oxygen (HO2S) Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Heated oxygen sensor .............................................................................................................................................................. 36-46 Nm (26-34 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #1 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2360 Heated Oxygen Sensors The Heated Oxygen Sensor #1 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2361 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #2 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2362 Heated Oxygen Sensors The Heated Oxygen Sensor #2 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2363 HO2S Diagram Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2364 Heated Oxygen (HO2S) Sensor: Description and Operation Heated Oxygen Sensor PURPOSE The Heated Exhaust Gas Oxygen Sensor(HO2S) detects the presence of oxygen in the exhaust system and produces a variable voltage according to the amount of oxygen present. When operating in closed loop the Powertrain Control Module (PCM) monitors this input and correspondingly changes the duration of the fuel injection pulse width to achieve an air/fuel ratio of 14.7:1. CONSTRUCTION The sensor is a zirconium dioxide ceramic thimble with a platinum surface electrode. The sensor is threaded into the exhaust manifold with a sampling tip extending into the exhaust stream. Heated Oxygen Sensor Operation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2365 OPERATION The zirconium dioxide in the sensor is electrically sensitive to differences in the amount of oxygen present between two sources. The outside of the sensor is vented to the atmosphere while the inside is exposed to the exhaust stream. The differing amounts of oxygen present between the two sources causes the sensor to generate a voltage. A rich fuel mixture will result in a low level of oxygen present in the exhaust. This will produce a larger difference in oxygen levels sensed by the HO2S which will result in a higher voltage being produced. A lean fuel mixture will result in a high level of oxygen present in the exhaust. This will produce a smaller difference in oxygen levels sensed by the HO2S which will result in a lower voltage being produced. Normal operating range for the HO2S is 0.0 volts (lean condition) to 1.1 volts (rich condition). The HO2S temperature must be above 600°F to operate properly. To minimize heat up time, a heating element is incorporated into the sensor. Heated Oxygen Sensor The HO2S uses a 4 wire connection. - HO2S wire is the sensor output. - SIG RTN is the sensor ground. - 12.0 volt power supply for the sensor heater, from the Ignition Run circuit. - Ground wire for the sensor heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2366 Heated Oxygen (HO2S) Sensor: Service and Repair Heated Oxygen Sensors REMOVAL NOTE: If excessive force is needed to remove Heated Oxygen Sensor (HO2S), lubricate HO2Ss with penetrating lubricant E8AZ-19A501-B or equivalent prior to removal. 1. Disconnect negative battery cable. 2. Disconnect HO2Ss from engine control sensor extension wiring (12A690). 3. Raise vehicle on hoist. 4. Remove HO2Ss. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten HO2Ss to 36-46 Nm (26-34 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2371 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2372 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2377 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2378 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2379 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2380 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2381 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2382 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2383 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2386 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2387 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2388 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2389 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2390 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2394 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2395 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Sensor resistance ................................................................................................................................ ............................................................. 190-250 ohms Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2399 Vehicle Speed Sensor: Locations Component Locations The Vehicle Speed Sensor is attached to transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2400 Vehicle Speed Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2401 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) PURPOSE The Vehicle Speed Sensor (VSS) signal is used by the Powertrain Control Module (PCM) to determine vehicle speed. OPERATION The VSS produces AC signals proportional to vehicle speed. This signal is sent to the PCM and is converted into a vehicle speed value, stored in RAM memory. The PCM utilizes this value to aid in controlling torque converter lock-up, coolant fan control, vehicle speed control, air/fuel ratio and ignition timing. Vehicle Speed Sensor Schematic CONSTRUCTION The VSS is a variable reluctance sensor that generates a sine wave type waveform with a frequency that is proportional to the speed of the vehicle. RELATED DIAGNOSTIC TROUBLE CODES DTC 29/452 - PCM detected an error in the VSS output (continuous memory code). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2407 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2408 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2418 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2419 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2425 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2426 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2431 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2437 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 2440 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2441 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2442 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2443 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2444 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations INERTIA FUEL SHUTOFF SWITCH LOCATION Inertia Fuel Shutoff Switch Location Located on the toe-board to the right of the transmission hump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 2448 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "OFF" in the event of a collision. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump looses power. The inertia switch must then be manually reset before the engine can be restarted. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 2449 Fuel Pump Inertia Switch: Service and Repair WARNING: Do not reset the inertia switch button if you see or smell fuel. 1. Turn ignition switch to OFF. 2. Check for leaking fuel in the engine compartment, fuel lines and fuel tank. 3. If no fuel is apparent, reset the Inertia Fuel Shutoff (IFS) switch by pushing the reset button on top of switch. 4. Turn ignition switch to START for a few seconds, then to OFF. 5. Again, check for leaking fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2454 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2455 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2456 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2457 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2458 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2459 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2460 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2463 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2464 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2465 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2466 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2467 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2474 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2475 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2476 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2477 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2478 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 2479 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2484 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2485 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2488 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2489 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2490 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2491 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2492 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2493 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2494 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2495 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2496 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2497 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2498 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The Profile Ignition Pickup (PIP) sensor is a Hall-effect type switch located in the distributor. It sends the Powertrain Control Module (PCM) information on engine speed and crankshaft position. The Hall device operates by the manipulation of magnetic fields. When a rotor vane ENTERS the space between the two halves of the stator pick-up, the magnetic field is altered, turning ON the signal to the PCM. When the vane LEAVES the stator gap, the magnetic field returns to normal, and the signal to the PCM is turned OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 2510 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 2511 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 2517 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 2518 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 2519 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 2520 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 2526 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 2530 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 2531 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Air/fuel mixture requirement is computer controlled and not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments Idle Speed: Adjustments NOTE: Curb and fast idle speeds are controlled by the Powertrain Control Module (PCM) and Idle Air Control (IAC) valve assembly. The IAC valve and idle speed is not adjustable. A large increase or decrease in closed plate airflow from the calibrated level will not allow effective idle speed control. Throttle Body Assembly Throttle bodies with sludge tolerant design are identified with a yellow/black decal. The throttle body must not be cleaned inside the bore, as this cleaning will impair the sensitive coating. Sludge accumulation will not affect the idle air flow. The cleaning procedure for the IAC valve still applies. RPM LIMIT CHECK PROCEDURE - Self-Test constant tone STAR tester or equivalent scanner required 1. Activate engine running Self-Test. 2. After diagnostic trouble code 11 or 111 has been displayed, unlatch and within 4 seconds latch the Self-Test Input (STI) button. 3. A single pulse code indicates the entry mode, then observe the Self-Test Output (STO) of the STAR tester. - A constant tone, solid light or "STO LO" readout indicates base idle rpm is within range. - Beeping tone, flashing light, or STO LO readout at 8.0 Hz indicates Throttle Position (TP) is out of range due to over adjustment. - Beeping tone, flashing light, or STO LO readout at 4.0 Hz indicates base idle rpm is too fast. - Beeping tone, flashing light, or STO LO readout at 1.0 Hz indicates base idle is too slow. 4. To exit test, unlatch STI button, then wait 4 seconds for reinitialization (after 10 minutes it will exit by itself). 5. If the idle rpm (engine warm, in Neutral, A/C "Off") is not within limits, refer to Testing and Inspection / Procedures / Air Induction Diagnosis for other possible causes of idle problem. See: Fuel Delivery and Air Induction/Testing and Inspection/Pinpoint Tests/AIS - Air Induction Diagnosis Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Engine - Water Entry Through Air Intake System Air Cleaner Fresh Air Duct/Hose: Technical Service Bulletins Engine - Water Entry Through Air Intake System Article No. 94-3-8 02/09/94 ^ AIR INTAKE - 2.9L, 3.0L, 4.0L EFI ENGINES - WATER ENTRY THROUGH AIR INTAKE SYSTEM ^ ENGINE - 2.9L, 3.0L, 4.0L EFI - POSSIBLE INTERNAL DAMAGE FROM WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK: 1986-90 BRONCO II 1986-94 RANGER 1991-94 EXPLORER This article is being republished in its entirety to add 1993-94 4.0L Ranger, 1993-94 3.0L Ranger and 1993-94 4.0L Explorer vehicles. ISSUE: Reports have been received of internal engine damage caused by water entering the engine through the air intake system. This condition may occur when the vehicle is driven in normal wet conditions, such as water splash/spray from other vehicles, or when driven through shallow water. Improvements were made to the EFI engine air intake systems that have greatly reduced the number of reported incidences. ACTION: Dealers should be assured that warranty repairs will be covered unless there Is evidence of owner misuse. This warranty repair policy will remain effective unless you are notified that a waterproof air intake system has been released. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-21-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 2543 Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL NOTE: The heat supply plenum door actuating motor and hose are not serviceable items. Repair requires the replacement of the engine air cleaner intake tube and duct. 1. Remove engine air cleaner. 2. Remove heat supply hose from exhaust manifold engine air cleaner duct shroud and tube and engine air cleaner intake tube and duct. 3. Remove one retaining screw from radiator support (baffle). 4. Remove actuator motor vacuum supply hose from bi-metal sensor in engine air cleaner assembly upper cover. 5. Remove engine air cleaner intake tube and duct from vehicle. INSTALLATION 1. Position engine air cleaner intake tube and duct and install retaining screw. 2. Reassemble engine air cleaner as described in this section. 3. Connect engine air cleaner intake tube and duct to engine air cleaner. Make sure engine air cleaner intake tube and duct snaps into place. 4. Connect vacuum hose to bi-metal sensor. 5. Install heat supply hose assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation Air Cleaner Element: Description and Operation PURPOSE Filters out unwanted dust, dirt and debris. CONSTRUCTION Chemically-treated, pleated paper element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 2547 Air Cleaner Element: Service and Repair Air Intake System REMOVAL 1. Loosen outlet tube clamps from air cleaner cover and throttle body. Remove the outlet tube. 2. Disconnect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 3. Disconnect the Mass Air Flow (MAF) sensor electrical connection. 4. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 5. Remove the two air cleaner cover retaining screws, then the air cleaner cover. 6. Remove the air filter element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 2548 INSTALLATION 1. Install the air filter element. 2. Remove the air cleaner cover, then the two air cleaner cover retaining screws. Tighten the screws to 3 Nm (26 lb in). 3. Connect the IAT sensor electrical connector. 4. Connect the MAF sensor electrical connection. 5. Connect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 6. Install the outlet tube. Tighten the outlet tube clamps at the air cleaner cover and throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Page 2556 Spark Plug Wire Assembly Vin X V6 Firing Order: 1 4 2 5 3 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations Ignition Timing Connector: Locations Connector Location The SPOUT connector shorting bar (C107), is located at the RF corner of the engine compartment, near EDIS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation Ignition Timing Connector: Description and Operation SPOUT / SAW Connector Operation Spout/SAW Connector DESCRIPTION The Spark Angle Word (SAW),or Spark Output (SPOUT) connector is used to open and close the circuit between the Powertrain Control Module (PCM)and the Ignition Control Module (ICM) for checking base timing. OPERATION When the SPOUT or SAW connector is inserted in the harness connector, the ICM operates according to PCM timing data (computed timing). When the SPOUT or SAW connector is removed from the harness connector, the ICM operates on the Profile Ignition Pickup (PIP) signal only (base timing). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation > Page 2563 Ignition Timing Connector: Description and Operation Octane Adjustment Switch Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2570 Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2571 Ignition Cable: Description and Operation PURPOSE Conducts high voltage from the ignition coil and deliver to each spark plug in proper sequence. CONSTRUCTION Secondary ignition wires are constructed with a carbon impregnated, multi-filament synthetic fiber core. To endure under hood temperatures, the core is surrounded by heat resistant rubber insulation. Built-in internal resistance suppresses radio static and eliminates interference. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Locations > Page 2572 Ignition Cable: Service and Repair Spark Plug Wire Assembly REMOVAL: 1. When removing spark plug wires from the spark plugs, use the spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug insulator to free the boot. 2. Use the special tool or equivalent to pull the boot from the plug. Do not pull on the wire directly, as it may become separated from the connector inside the boot. 3. To remove the wires from the coil pack, squeeze the locking tabs of the coil wire retainer and remove using a twisting and pulling motion. Do not pull on the wire. INSTALLATION: CAUTION: Proper installation of spark plug wires is critical to vehicle operation. If one spark plug wire is not properly installed on the spark plug or ignition coil, both spark plugs connected to that coil may not fire under load. 1. Whenever a high tension wire is removed for any reason from a spark plug or ignition coil, or a new high tension wire is installed, Silicone Dielectric Compound D7AZ-19A331-A or equivalent must be applied to the boot prior to installation. Using a small tool, coat the entire interior surface of the boot. 2. Install each wire on the proper ignition coil terminal. The terminal cylinder numbers are identified on the ignition coil pack. Ensure that both coil boot retainer locking tabs have engaged. 3. Remove the wire retaining brackets from the old wiring set and install the brackets on the new wires in the same position. Install the wires and retaining brackets on the engine. 4. Connect the wires to the proper Spark plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Platinum Spark Plugs - Identification/Location Spark Plug: Technical Service Bulletins Platinum Spark Plugs - Identification/Location Article No. 94-2-8 01/26/94 ^ IGNITION SYSTEM - ELECTRONIC IGNITION (EI) PLATINUM ENHANCED SPARK PLUGS 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L ENGINES ^ ENGINE - 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L - PLATINUM ENHANCED SPARK PLUG LOCATIONS FORD: 1994 ESCORT, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Three (3) different unique styles of platinum enhanced spark plugs are produced for vehicles with Electronic Ignition (EI). Each style is distinguished by their part number suffix letters. ^ The suffix letter "P" indicates the center electrode is enhanced with platinum. ^ The suffix letter "PG" indicates the ground (side) electrode is enhanced with platinum. ^ The suffix letter "PP" indicates double platinum enhancement on both the ground (side) and center electrode. ACTION: If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter "PP" as shown on the engine decal. Refer to the following Platinum Enhanced Spark Plug Replacement Chart for correct parts usage. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000, 623000, 690000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Plug Type .......................................................... ............................................................................................................................. Motorcraft AWSF-42PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 2579 Spark Plug: Specifications Tightening Torque SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Tightening Torque ............................................. .................................................................................................................................... 7-15 ft lb (9-20 Nm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2580 Spark Plug: Description and Operation PURPOSE Spark plugs provide the path for secondary ignition system high voltage to flow to ground. OPERATION Voltage arcing between plug center and ground electrode produces the spark to ignite the air/fuel mixture. CONSTRUCTION Many spark plugs are made with an internal resistor, designed to reduce ignition system electrical interference with entertainment systems and computerized devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2581 Spark Plug: Testing and Inspection Testing For Spark 1. Remove the spark plug. 2. Connect the spark plug to the spark plug wire. 3. Hold the spark plug with insulated pliers 0.20-0.40 in (5-10 mm) from a ground. 4. Crank the engine and verify that there is a strong blue spark. If there Is no spark, replace the spark plug. Spark Plug 5. Check the following points. If a problem is found, replace the spark plug. ^ Damaged insulation ^ Worn electrodes ^ Carbon deposits. (If cleaning is necessary, use a plug cleaner or a wire brush. Clean the upper insulator also.) ^ Damaged gasket. ^ Burnt condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure ....................................................................................................................... PSI of lowest cylinder must be within 75% of highest Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations Valve Arrangement (Front To Rear) ........................................................................................................................................................... L.H. I-E-I-E-I-E Valve Arrangement (Front To Rear) ........................................................................................................................................................... R.H. E-I-E-I-E-I Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 2588 Valve Clearance: Adjustments The hydraulic roller tappets have non-adjustable rocker arms. The tappets are not adjustable, and if found to be excessively worn or noisy, should be tested and replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions A/C Signal: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 A/C Signal Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Page 2602 A/C Signal: Description and Operation PURPOSE The A/C signal is an input to the Powertrain Control Module (PCM) which informs it that a request for A/C operation has been made. The PCM then determines if all of the requirements for A/C operation have been met: The engine must be running. - The engine must not be overheating. - The engine must not be operating at wide open throttle. If these conditions are met the PCM will increase idle speed and then energize the A/C relay. OPERATION With the A/C demand switch closed and the A/C clutch cyclic pressure switch shut, battery voltage will be placed on circuit ACCS (10), informing the PCM of an A/C request. A/C clutch operation will not occur until the PCM grounds circuit WAC (54). RELATED DIAGNOSTIC TROUBLE CODES DTC 539 - A/C request during self test procedure. DTC 559 - A/C ON circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2611 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2612 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2618 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2619 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2624 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2630 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 2633 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2634 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2635 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2636 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2637 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications Intake Air Temperature Sensor: Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values Notes: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Ambient temperature should be above 10°C (50°F) to receive acceptable input from the Intake Air Temperature (IAT) sensor. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications > Page 2642 Intake Air Temperature Sensor: Mechanical Specifications TORQUE SPECIFICATION Intake air temperature sensor ......................................................................................................................................................... 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2643 Intake Air Temperature Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2644 Intake Air Temperature Sensor: Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2645 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the incoming air flow. The Powertrain Control Module (PCM) uses this information to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The IAT is a two lead thermistor type sensor with a negative temperature coefficient and is located in the intake air flow path. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the IAT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the incoming air increases the resistance of the IAT decreases and the voltage drop across the IAT decreases. A decrease in air temperature will increase the resistance of the IAT and raise the voltage drop across the sensor. The normal operating range of the IAT is 3.50 volts (50°F) to 1.02 volts (158°F). Note: Due to its negative temperature coefficient minor increases in resistance across the IAT circuit harness and ground connections can result in temperature values that are much lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 64/112 - The IAT sensor output is less than the self-test minimum, 0.2 volts. DTC 54/113 - The IAT sensor output is greater than the self-test maximum, 4.6 volts. DTC 24/114 - The IAT sensor output is out of self-test range, 0.3-3.7 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2646 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect electrical connector from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from intake manifold. INSTALLATION 1. To install, reverse removal procedure. 2. Tighten IAT sensor to 8-13 Nm (6-8 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. 3. Connect negative battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions Brake On/Off (BOO) Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Brake On/Off (BOO) Signal Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake On/Off (BOO) Switch <--> [Brake Signal] > Component Information > Diagrams > Page 2659 Brake On/Off (BOO) Switch: Description and Operation PURPOSE The Brake On Off (BOO) signal is an input to the Powertrain Control Module (PCM), informing it of brake operation. The PCM uses this data to modify the operation of the torque converter clutch (if equipped), A/C compressor (if equipped), and idle speed during periods of deceleration, and idle with the brakes applied. Stoplight Switch OPERATION The PCM receives a signal (battery voltage) directly from the stoplamp switch when the the brake pedal is applied. RELATED TROUBLE CODES DTC 74/536 - BOO signal did not cycle high and low when the brake pedal was depressed during the Key On Engine Running (KOER) self-test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2665 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2666 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2667 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2668 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2669 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2670 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions Clutch Pedal Position Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2675 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2676 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2677 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2678 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2679 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2680 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2681 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2682 Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2683 Neutral Drive Input Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Page 2684 Clutch Pedal Position Switch: Description and Operation PURPOSE The Clutch Pedal Position (CPP) switch provides an input to the Powertrain Control Module (PCM), allowing it to compensate for changes in engine load resulting from clutch operation. The PCM adjusts the idle speed and air/fuel ratio according to input from the CPP switch. OPERATION A 5.0 volt reference signal is applied to the CPP from the PCM. The CPP switch is open with the clutch pedal up and closed when down. When the switch is closed it applies ground, through the signal return circuit, to the CPP circuit, informing the PCM that the clutch pedal is depressed. RELATED DIAGNOSTIC TROUBLE CODES DTC 528 - CPP circuit failure, during Key On Engine OFF (KOEO) self-test or while cranking the PCM sensed a high voltage (clutch pedal not depressed) on the CPP circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2689 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2690 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2691 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2692 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2693 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2698 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2699 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2710 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2711 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2712 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations Cylinder Identification Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Cylinder Identification Sensor (CID), or Camshaft Position Sensor (CMP) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations > Page 2716 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal Cylinder Identification Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2719 Cylinder Identification Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2720 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2721 Cylinder Identification Sensor: Testing and Inspection Refer to Computers and Controls: System Diagnosis: Flow of Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2722 Cylinder Identification Sensor: Service and Repair For California, Sequential Fuel Injected (SFI) Models Only REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2723 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2724 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2725 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Component Locations The VIP Data Link Connector is located at RH rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2729 VIP Data Link Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 2730 Data Link Connector: Description and Operation PURPOSE The data link connector provides an input and output path to the Powertrain Control Module (PCM). This allows for the following functions: PCM Serial Data Through the use of a scan tool information concerning sensor input values and PCM outputs can be directly accessed. Diagnostic Trouble Codes Diagnostic trouble codes may be retrieved or cleared with the use of a scan tool or manually with the use of a high impedance analog voltmeter. Self-Tests Initiation of the self-test features of the PCM can be performed manually or with the use of a scan tool. CONSTRUCTION The data link connector is composed of two connectors. The larger connection is a 6 terminal connector used to provide access to the PCM. The smaller connection is a single pigtail connector which is used to ground terminals on the 6 terminal connector when initiating self-tests or accessing diagnostic trouble codes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Component Locations The Powertrain Control Module (PCM) is located under dash, at RH kick panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Diagrams Connector Views Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2736 PCM Connector View Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2737 Powertrain Control Module: Diagrams Terminal Identification Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2738 Powertrain Control Module: Description and Operation PURPOSE The Powertrain Control Module (PCM) monitors the signals from various input sensors and calculates the proper operating strategy for the engine operating conditions. In addition to normal operating strategy the PCM calculates/learns an adaptive strategy that compensates for normal wearing and aging of components. The PCM also provides for self-diagnostic testing. When the ignition is turned on the PCM is continuously checking its inputs and outputs for values out of specification. Any discrepancies are recorded as diagnostic trouble codes. The PCM also provides for operator initiated self-tests. These tests check for specific input values and output states under defined conditions. Note: Incorrect testing conditions and minor procedural deviations often result in false trouble codes and inaccurate information. When initiating self-tests technicians should verify that all required conditions are met. OPERATION The PCM continuously monitors input signals and compares these values to calibration information stored in its memory. The PCM's calibration assembly contains the necessary programming to fine-tune the PCM's engine calibration commands to the vehicle's weight, axle ratio, and transmission application. The calibration assembly is an integral part of the PCM and is not replaceable. The PCM determines the correct operating strategy and makes the necessary corrections to its output signals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure Powertrain Control Module: Reset Procedure KEEP ALIVE MEMORY AND ADAPTIVE STRATEGY The EEC-IV system constantly monitors and adjusts the PCM calibration to correct for normal wear and aging of components. The PCM uses these calibration adjustments to shift fuel delivery calculations and idle speed specifications to compensate for the aging of the vehicle. When an Electronic Engine Controls (EEC) system component is replaced, the Keep Alive Memory (KAM) should be cleared to erase the information stored by the processor from the original component. CLEARING KEEP ALIVE MEMORY To clear the KAM, disconnect the battery negative terminal for five minutes or more (preferably 15 minutes). ADAPTIVE STRATEGY RELEARN PROCEDURE After repairs have been made and the KAM cleared drive the the vehicle for at least ten miles to allow the PCM to relearn the values for optimum performance. NOTE: During the ten mile relearn drive, the vehicle may exhibit some driveability symptoms. These should be eliminated when the KAM has relearned the operating values. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure > Page 2741 Powertrain Control Module: Removal and Replacement Powertrain Control Module NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REMOVAL 1. Open hood and disconnect negative battery cable. 2. Remove two screws and right cowl side panel. 3. Disconnect PCM electrical connector. 4. Remove three screws and PCM bracket. 5. Disconnect PCM from connector and remove. INSTALLATION To install PCM, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications Idle Air Control (IAC) Valve: Electrical Specifications IDLE AIR CONTROL (IAC) SOLENOID Solenoid resistance ............................................................................................................................. ................................................... 6.0-13.0 ohms Solenoid to case resistance ................................................................................................................................................... greater than 10,000 ohms IAC signal from PCM ........................................................................................................................................................ 3.0-11.5 volts at 3000 rpm Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications > Page 2746 Idle Air Control (IAC) Valve: Mechanical Specifications IDLE AIR CONTROL VALVE TORQUE SPECIFICATION Retaining screws ................................................................................................................................. ...................................... 9-11 Nm (80-97 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2747 Idle Air Control (IAC) Valve: Diagrams IAC Solenoid CIRCUIT / WIRE COLOR IAC / white/light blue VPWR / red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 2748 Idle Air Control (IAC) Valve: Description and Operation PURPOSE The Idle Air Control (IAC) solenoid allows the Powertrain Control Module (PCM) to accurately control engine idle speed under a variety of conditions. The IAC solenoid is driven by an output signal from the PCM and allows intake airflow to bypass the throttle plates. In addition to normal idle speed control the IAC solenoid also functions as a deceleration dashpot and allows for idle speed changes during periods of increased engine load (A/C, electrical). The IAC solenoid also plays an integral role in Adaptive Strategy correction. The PCM monitors the engine condition and adjusts the IAC calibration to correct for wear and aging of components. NOTE: Whenever an IAC component is replaced or cleaned it is recommended that the Keep Alive Memory (KAM) be be cleared. The vehicle may exhibit idle concerns until new adaptive values are learned. CONSTRUCTION A duty cycle driven solenoid is directly linked to a reverse seated pintle valve. Hitachi Idle Air Control (IAC) Valve And Solenoid Hitachi With Vent/Filter This type of IAC solenoid is not serviceable and cannot be cleaned. Idle Air Control Solenoid OPERATION The IAC solenoid receives a 12 volt signal from circuit VPWR. The ground supply to the IAC solenoid is controlled by the PCM. The PCM controls the amount of IAC operation by varying the duty cycle of the ground signal. The IAC solenoid is linked directly to a pintle valve which controls the amount of intake airflow allowed to bypass the throttle plates. RELATED DIAGNOSTIC TROUBLE CODES DTC 412 Indicates that during the Key On Engine Running (KOER) self-test, engine rpm could not be controlled within the self-test limit band. DTC 415 Indicates the IAC adaptive learning has reached the minimum learning limit (the valve is reducing air flow as much as possible). DTC 416 Indicates the IAC adaptive learning has reached the maximum learning limit (the valve is admitting as much air flow as possible). NOTE: Idle speed surging commonly results when the IAC solenoid reaches the limits of its operation. The IAC solenoid cannot compensate for the required change in idle speed which results in the engine surging between the upper and lower limits of the IAC system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures Idle Air Control (IAC) Valve: Procedures CAUTION: The Idle Air Control (IAC) valve CANNOT be cleaned unless removed from the engine. CAUTION: Do not clean black plastic IAC valves. Use only specified cleaner. Do not spray directly on throttle plate or use any type of scrubbing method. Do not run engines of vehicles with mass airflow sensors during cleaning. Cleanable/Non-Cleanable Idle Air Control Valves RECOMMENDED CLEANING PROCEDURE 1. Ensure IAC valve is operating properly. 2. Remove air cleaner outlet tube. 3. Disconnect fuel charging wiring connector from IAC valve. 4. Connect Rotunda Air Bypass Actuator 113-00009 and Injector Tester/Cleaner 113-00001 or equivalent. 5. Start the actuator. Do not start engines of vehicles equipped with mass airflow sensors. 6. Spray Carburetor Tune-Up Cleaner D9AZ-19579-BA (ESR-M14P9-A) or equivalent into IAC valve passage for five seconds while actuator is operating. 7. Turn the actuator off. Allow solvent to soak for 15 minutes. 8. Turn actuator on. 9. Spray carburetor cleaner into IAC valve passage for no more than six seconds. 10. Turn actuator off. 11. Install air cleaner outlet tube. Start actuator and engine and run engine for one minute to dry out solvent residue. 12. Disconnect actuator from IAC valve. Connect fuel charging wiring connector to IAC valve. 13. Start engine and check for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 2751 Idle Air Control (IAC) Valve: Removal and Replacement Idle Air Control Valve REMOVAL 1. Disconnect the Idle Air Control (IAC) valve connector from the fuel charging wiring. 2. Remove the two IAC valve retaining bolts. 3. Remove the IAC valve and IAC gasket. NOTE: If scraping is necessary, be careful not to damage IAC valve, throttle body gasket surfaces or drop material into throttle body. INSTALLATION 1. Make sure that both throttle body and valve gasket surfaces are clean. 2. Install IAC gasket on throttle body surface and mount IAC valve, securing it with two retaining screws. Tighten to 9-11 Nm (80-97 in lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2755 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2756 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Malfunction Indicator Lamp: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 2761 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Page 2762 Malfunction Indicator Lamp: Description and Operation PURPOSE To alert the vehicle operator of a malfunction in the electronic engine control system. OPERATION The Malfunction Indicator will light with the ignition switch in the ON position prior to cranking, and goes out when the engine starts. If a fault develops, the powertrain control module will turn the indicator ON. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Heated Oxygen (HO2S) Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2767 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2768 Heated Oxygen (HO2S) Sensor: Technical Service Bulletins Heated Exhaust Gas Oxygen Sensor Application Chart Article No. 94-16-9 08/10/94 EXHAUST - HEATED OXYGEN SENSOR (H02S) - APPLICATION CHART FORD: 1991-94 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1991-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1993-94 MARK VIII LIGHT TRUCK: 1991-94 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER MEDIUM/HEAVY TRUCK: 1991 F & B SERIES ISSUE: Quick Reference Heated Oxygen Sensor (H02S) Application Charts have been developed to assist technicians and parts managers in correct parts usage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2769 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2770 ACTION: Refer to the appropriate Quick Reference Heated Oxygen Sensor (HO2S) Application Chart for Passenger Car or Truck, Figures 1 and 2, to make sure that the correct service sensor is installed. In some cases, new applications are shown. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2771 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications Heated Oxygen (HO2S) Sensor: Electrical Specifications HEATER ELEMENT RESISTANCE Hot to warm ......................................................................................................................................... .................................................. 5.0-30.0 ohms Room temperature .................................................... ............................................................................................................................... 2.0-5.0 ohms HO2S SWITCHING HO2S signal ........................................................................................................................................ .......................... 0.3-0.9 volts within 3 seconds After driving 55 mph for 5 minutes. Testing procedures may be found under System Testing / Pinpoint tests. See: Testing and Inspection/Pinpoint Tests/H - Fuel Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications > Page 2774 Heated Oxygen (HO2S) Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Heated oxygen sensor .............................................................................................................................................................. 36-46 Nm (26-34 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #1 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2777 Heated Oxygen Sensors The Heated Oxygen Sensor #1 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2778 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #2 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2779 Heated Oxygen Sensors The Heated Oxygen Sensor #2 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2780 HO2S Diagram Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2781 Heated Oxygen (HO2S) Sensor: Description and Operation Heated Oxygen Sensor PURPOSE The Heated Exhaust Gas Oxygen Sensor(HO2S) detects the presence of oxygen in the exhaust system and produces a variable voltage according to the amount of oxygen present. When operating in closed loop the Powertrain Control Module (PCM) monitors this input and correspondingly changes the duration of the fuel injection pulse width to achieve an air/fuel ratio of 14.7:1. CONSTRUCTION The sensor is a zirconium dioxide ceramic thimble with a platinum surface electrode. The sensor is threaded into the exhaust manifold with a sampling tip extending into the exhaust stream. Heated Oxygen Sensor Operation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2782 OPERATION The zirconium dioxide in the sensor is electrically sensitive to differences in the amount of oxygen present between two sources. The outside of the sensor is vented to the atmosphere while the inside is exposed to the exhaust stream. The differing amounts of oxygen present between the two sources causes the sensor to generate a voltage. A rich fuel mixture will result in a low level of oxygen present in the exhaust. This will produce a larger difference in oxygen levels sensed by the HO2S which will result in a higher voltage being produced. A lean fuel mixture will result in a high level of oxygen present in the exhaust. This will produce a smaller difference in oxygen levels sensed by the HO2S which will result in a lower voltage being produced. Normal operating range for the HO2S is 0.0 volts (lean condition) to 1.1 volts (rich condition). The HO2S temperature must be above 600°F to operate properly. To minimize heat up time, a heating element is incorporated into the sensor. Heated Oxygen Sensor The HO2S uses a 4 wire connection. - HO2S wire is the sensor output. - SIG RTN is the sensor ground. - 12.0 volt power supply for the sensor heater, from the Ignition Run circuit. - Ground wire for the sensor heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2783 Heated Oxygen (HO2S) Sensor: Service and Repair Heated Oxygen Sensors REMOVAL NOTE: If excessive force is needed to remove Heated Oxygen Sensor (HO2S), lubricate HO2Ss with penetrating lubricant E8AZ-19A501-B or equivalent prior to removal. 1. Disconnect negative battery cable. 2. Disconnect HO2Ss from engine control sensor extension wiring (12A690). 3. Raise vehicle on hoist. 4. Remove HO2Ss. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten HO2Ss to 36-46 Nm (26-34 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2788 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2789 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Locations Powertrain Control Module: Locations Component Locations The Powertrain Control Module (PCM) is located under dash, at RH kick panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views Powertrain Control Module: Diagrams Connector Views Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2796 PCM Connector View Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Connector Views > Page 2797 Powertrain Control Module: Diagrams Terminal Identification Powertrain Control Module Connector Pin Useage Powertrain Control Module Connector Pin Useage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 2798 Powertrain Control Module: Description and Operation PURPOSE The Powertrain Control Module (PCM) monitors the signals from various input sensors and calculates the proper operating strategy for the engine operating conditions. In addition to normal operating strategy the PCM calculates/learns an adaptive strategy that compensates for normal wearing and aging of components. The PCM also provides for self-diagnostic testing. When the ignition is turned on the PCM is continuously checking its inputs and outputs for values out of specification. Any discrepancies are recorded as diagnostic trouble codes. The PCM also provides for operator initiated self-tests. These tests check for specific input values and output states under defined conditions. Note: Incorrect testing conditions and minor procedural deviations often result in false trouble codes and inaccurate information. When initiating self-tests technicians should verify that all required conditions are met. OPERATION The PCM continuously monitors input signals and compares these values to calibration information stored in its memory. The PCM's calibration assembly contains the necessary programming to fine-tune the PCM's engine calibration commands to the vehicle's weight, axle ratio, and transmission application. The calibration assembly is an integral part of the PCM and is not replaceable. The PCM determines the correct operating strategy and makes the necessary corrections to its output signals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure Powertrain Control Module: Reset Procedure KEEP ALIVE MEMORY AND ADAPTIVE STRATEGY The EEC-IV system constantly monitors and adjusts the PCM calibration to correct for normal wear and aging of components. The PCM uses these calibration adjustments to shift fuel delivery calculations and idle speed specifications to compensate for the aging of the vehicle. When an Electronic Engine Controls (EEC) system component is replaced, the Keep Alive Memory (KAM) should be cleared to erase the information stored by the processor from the original component. CLEARING KEEP ALIVE MEMORY To clear the KAM, disconnect the battery negative terminal for five minutes or more (preferably 15 minutes). ADAPTIVE STRATEGY RELEARN PROCEDURE After repairs have been made and the KAM cleared drive the the vehicle for at least ten miles to allow the PCM to relearn the values for optimum performance. NOTE: During the ten mile relearn drive, the vehicle may exhibit some driveability symptoms. These should be eliminated when the KAM has relearned the operating values. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and Repair > Reset Procedure > Page 2801 Powertrain Control Module: Removal and Replacement Powertrain Control Module NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. REMOVAL 1. Open hood and disconnect negative battery cable. 2. Remove two screws and right cowl side panel. 3. Disconnect PCM electrical connector. 4. Remove three screws and PCM bracket. 5. Disconnect PCM from connector and remove. INSTALLATION To install PCM, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2805 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2806 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2816 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2817 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2823 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 2824 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2829 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 2835 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 2838 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2839 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2840 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2841 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 2842 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2848 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2849 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2850 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2851 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2852 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Page 2853 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions Clutch Pedal Position Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Neutral Drive Input Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Pedal Position Switch <--> [Clutch Switch, ECM] > Component Information > Diagrams > Page 2867 Clutch Pedal Position Switch: Description and Operation PURPOSE The Clutch Pedal Position (CPP) switch provides an input to the Powertrain Control Module (PCM), allowing it to compensate for changes in engine load resulting from clutch operation. The PCM adjusts the idle speed and air/fuel ratio according to input from the CPP switch. OPERATION A 5.0 volt reference signal is applied to the CPP from the PCM. The CPP switch is open with the clutch pedal up and closed when down. When the switch is closed it applies ground, through the signal return circuit, to the CPP circuit, informing the PCM that the clutch pedal is depressed. RELATED DIAGNOSTIC TROUBLE CODES DTC 528 - CPP circuit failure, during Key On Engine OFF (KOEO) self-test or while cranking the PCM sensed a high voltage (clutch pedal not depressed) on the CPP circuit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values NOTES: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2872 Coolant Temperature Sensor/Switch (For Computer): Mechanical Specifications TORQUE SPECIFICATION Engine coolant temperature sensor ................................................................................................................................................ 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2873 Coolant Temperature Sensor/Switch (For Computer): Locations All Except Limited Edition And Electronic Group The Engine Coolant Temperature (ECT) Sensor is mounted on the front of engine, left of throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2874 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2875 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Engine Coolant Temperature (ECT) Sensor PURPOSE The Engine Coolant Temperature (ECT) sensor provides an input to the Powertrain Control Module (PCM). The PCM uses engine coolant temperature data to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The ECT is a two lead thermistor type sensor with a negative temperature coefficient. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the ECT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the engine coolant increases the resistance of the ECT sensor decreases and correspondingly the voltage drop across the ECT sensor is reduced. A decrease in engine coolant temperature will increase the resistance of the ECT and raise the voltage drop across the sensor. The normal operating range of the ECT is 3.50 volts (50°F) to 0.35 volts (230°F). Due to its negative temperature coefficient, poor electrical connections or minor increases in resistance across the ECT circuit harness and ground connections can result in temperature values that are lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 21/116 - The ECT sensor output is out of self-test range, 0.3-3.7 volts. DTC 61/117 - The ECT sensor output is less than the self-test minimum, 0.2 volts. DTC 51/118 - The ECT sensor output is greater than the self-test maximum, 4.6 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2876 Coolant Temperature Sensor/Switch (For Computer): Service and Repair REMOVAL NOTE: The Engine Coolant Temperature (ECT) sensor is located in the lower intake manifold near the water outlet connection. 1. Disconnect negative battery cable. 2. Partially drain cooling system. 3. Disconnect ECT sensor electrical connector. 4. Remove ECT sensor from lower intake manifold. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten the ECT sensor to 8-13 Nm (6-8 ft lb). 3. Refill cooling system. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2881 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 2882 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2893 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2894 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2895 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations Cylinder Identification Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Cylinder Identification Sensor (CID), or Camshaft Position Sensor (CMP) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Locations > Page 2899 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal Cylinder Identification Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2902 Cylinder Identification Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > 49 State/Federal > Page 2903 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2904 Cylinder Identification Sensor: Testing and Inspection Refer to Computers and Controls: System Diagnosis: Flow of Diagnosis. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2905 Cylinder Identification Sensor: Service and Repair For California, Sequential Fuel Injected (SFI) Models Only REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2906 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2907 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Cylinder Identification Sensor > Component Information > Description and Operation > Page 2908 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications Intake Air Temperature Sensor: Electrical Specifications Engine Coolant/Intake Air Temperature Sensor Values Notes: Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO Self-Test and greater than 82°C (180°F) to pass the KOER Self-Test. To accomplish this, the engine should be at normal operating temperature. Ambient temperature should be above 10°C (50°F) to receive acceptable input from the Intake Air Temperature (IAT) sensor. Voltage values were calculated for VREF=5.0 volts. These values may vary 16 percent due to sensor and VREF variations. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Electrical Specifications > Page 2913 Intake Air Temperature Sensor: Mechanical Specifications TORQUE SPECIFICATION Intake air temperature sensor ......................................................................................................................................................... 8-13 Nm (6-8 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2914 Intake Air Temperature Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2915 Intake Air Temperature Sensor: Diagrams Connector Views CIRCUIT / WIRE COLOR IAT 25 / gray SIG RTN 46 / gray/red ECT 7 / light green/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2916 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor PURPOSE The Intake Air Temperature (IAT) sensor measures the temperature of the incoming air flow. The Powertrain Control Module (PCM) uses this information to adjust the fuel injection base pulse width, EGR flow, and ignition timing. CONSTRUCTION The IAT is a two lead thermistor type sensor with a negative temperature coefficient and is located in the intake air flow path. Descriptive Schematic OPERATION The PCM applies a 5.0 volt reference voltage to the IAT signal lead while the signal return lead is connected to a common sensor ground. As the temperature of the incoming air increases the resistance of the IAT decreases and the voltage drop across the IAT decreases. A decrease in air temperature will increase the resistance of the IAT and raise the voltage drop across the sensor. The normal operating range of the IAT is 3.50 volts (50°F) to 1.02 volts (158°F). Note: Due to its negative temperature coefficient minor increases in resistance across the IAT circuit harness and ground connections can result in temperature values that are much lower than actual. RELATED DIAGNOSTIC TROUBLE CODES DTC 64/112 - The IAT sensor output is less than the self-test minimum, 0.2 volts. DTC 54/113 - The IAT sensor output is greater than the self-test maximum, 4.6 volts. DTC 24/114 - The IAT sensor output is out of self-test range, 0.3-3.7 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2917 Intake Air Temperature Sensor: Service and Repair Intake Air Temperature Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect electrical connector from Intake Air Temperature (IAT) sensor. 3. Remove IAT sensor from intake manifold. INSTALLATION 1. To install, reverse removal procedure. 2. Tighten IAT sensor to 8-13 Nm (6-8 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. 3. Connect negative battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Heated Oxygen (HO2S) Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2922 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2923 Heated Oxygen (HO2S) Sensor: Technical Service Bulletins Heated Exhaust Gas Oxygen Sensor Application Chart Article No. 94-16-9 08/10/94 EXHAUST - HEATED OXYGEN SENSOR (H02S) - APPLICATION CHART FORD: 1991-94 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1991-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1993-94 MARK VIII LIGHT TRUCK: 1991-94 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER MEDIUM/HEAVY TRUCK: 1991 F & B SERIES ISSUE: Quick Reference Heated Oxygen Sensor (H02S) Application Charts have been developed to assist technicians and parts managers in correct parts usage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2924 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2925 ACTION: Refer to the appropriate Quick Reference Heated Oxygen Sensor (HO2S) Application Chart for Passenger Car or Truck, Figures 1 and 2, to make sure that the correct service sensor is installed. In some cases, new applications are shown. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2926 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications Heated Oxygen (HO2S) Sensor: Electrical Specifications HEATER ELEMENT RESISTANCE Hot to warm ......................................................................................................................................... .................................................. 5.0-30.0 ohms Room temperature .................................................... ............................................................................................................................... 2.0-5.0 ohms HO2S SWITCHING HO2S signal ........................................................................................................................................ .......................... 0.3-0.9 volts within 3 seconds After driving 55 mph for 5 minutes. Testing procedures may be found under System Testing / Pinpoint tests. See: Testing and Inspection/Pinpoint Tests/H - Fuel Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Specifications > Electrical Specifications > Page 2929 Heated Oxygen (HO2S) Sensor: Mechanical Specifications TORQUE SPECIFICATIONS Heated oxygen sensor .............................................................................................................................................................. 36-46 Nm (26-34 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #1 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2932 Heated Oxygen Sensors The Heated Oxygen Sensor #1 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2933 Heated Oxygen (HO2S) Sensor: Locations Heated Oxygen Sensor #2 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Heated Oxygen Sensor #1 > Page 2934 Heated Oxygen Sensors The Heated Oxygen Sensor #2 is located on exhaust pipe of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2935 HO2S Diagram Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2936 Heated Oxygen (HO2S) Sensor: Description and Operation Heated Oxygen Sensor PURPOSE The Heated Exhaust Gas Oxygen Sensor(HO2S) detects the presence of oxygen in the exhaust system and produces a variable voltage according to the amount of oxygen present. When operating in closed loop the Powertrain Control Module (PCM) monitors this input and correspondingly changes the duration of the fuel injection pulse width to achieve an air/fuel ratio of 14.7:1. CONSTRUCTION The sensor is a zirconium dioxide ceramic thimble with a platinum surface electrode. The sensor is threaded into the exhaust manifold with a sampling tip extending into the exhaust stream. Heated Oxygen Sensor Operation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2937 OPERATION The zirconium dioxide in the sensor is electrically sensitive to differences in the amount of oxygen present between two sources. The outside of the sensor is vented to the atmosphere while the inside is exposed to the exhaust stream. The differing amounts of oxygen present between the two sources causes the sensor to generate a voltage. A rich fuel mixture will result in a low level of oxygen present in the exhaust. This will produce a larger difference in oxygen levels sensed by the HO2S which will result in a higher voltage being produced. A lean fuel mixture will result in a high level of oxygen present in the exhaust. This will produce a smaller difference in oxygen levels sensed by the HO2S which will result in a lower voltage being produced. Normal operating range for the HO2S is 0.0 volts (lean condition) to 1.1 volts (rich condition). The HO2S temperature must be above 600°F to operate properly. To minimize heat up time, a heating element is incorporated into the sensor. Heated Oxygen Sensor The HO2S uses a 4 wire connection. - HO2S wire is the sensor output. - SIG RTN is the sensor ground. - 12.0 volt power supply for the sensor heater, from the Ignition Run circuit. - Ground wire for the sensor heater. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen (HO2S) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 2938 Heated Oxygen (HO2S) Sensor: Service and Repair Heated Oxygen Sensors REMOVAL NOTE: If excessive force is needed to remove Heated Oxygen Sensor (HO2S), lubricate HO2Ss with penetrating lubricant E8AZ-19A501-B or equivalent prior to removal. 1. Disconnect negative battery cable. 2. Disconnect HO2Ss from engine control sensor extension wiring (12A690). 3. Raise vehicle on hoist. 4. Remove HO2Ss. INSTALLATION 1. To install, reverse removal procedures. 2. Tighten HO2Ss to 36-46 Nm (26-34 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 2943 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 2944 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2949 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2950 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2951 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2952 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2953 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2954 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2955 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2958 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2959 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2960 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2961 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2962 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2966 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2967 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Sensor resistance ................................................................................................................................ ............................................................. 190-250 ohms Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2971 Vehicle Speed Sensor: Locations Component Locations The Vehicle Speed Sensor is attached to transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2972 Vehicle Speed Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 2973 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) PURPOSE The Vehicle Speed Sensor (VSS) signal is used by the Powertrain Control Module (PCM) to determine vehicle speed. OPERATION The VSS produces AC signals proportional to vehicle speed. This signal is sent to the PCM and is converted into a vehicle speed value, stored in RAM memory. The PCM utilizes this value to aid in controlling torque converter lock-up, coolant fan control, vehicle speed control, air/fuel ratio and ignition timing. Vehicle Speed Sensor Schematic CONSTRUCTION The VSS is a variable reluctance sensor that generates a sine wave type waveform with a frequency that is proportional to the speed of the vehicle. RELATED DIAGNOSTIC TROUBLE CODES DTC 29/452 - PCM detected an error in the VSS output (continuous memory code). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2978 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2979 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2980 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2981 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2982 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2983 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 2984 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2987 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2988 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2989 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2990 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2991 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2995 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 2996 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Sensor resistance ................................................................................................................................ ............................................................. 190-250 ohms Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3000 Vehicle Speed Sensor: Locations Component Locations The Vehicle Speed Sensor is attached to transmission. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3001 Vehicle Speed Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications > Page 3002 Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor (VSS) PURPOSE The Vehicle Speed Sensor (VSS) signal is used by the Powertrain Control Module (PCM) to determine vehicle speed. OPERATION The VSS produces AC signals proportional to vehicle speed. This signal is sent to the PCM and is converted into a vehicle speed value, stored in RAM memory. The PCM utilizes this value to aid in controlling torque converter lock-up, coolant fan control, vehicle speed control, air/fuel ratio and ignition timing. Vehicle Speed Sensor Schematic CONSTRUCTION The VSS is a variable reluctance sensor that generates a sine wave type waveform with a frequency that is proportional to the speed of the vehicle. RELATED DIAGNOSTIC TROUBLE CODES DTC 29/452 - PCM detected an error in the VSS output (continuous memory code). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: Customer Interest Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3013 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Customer Interest for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3014 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise Catalyst Shield: All Technical Service Bulletins Exhaust System - Buzzing/Rattling Noise Article No. 98-20-10 10/12/98 ^ EXHAUST SYSTEM - LOOSE CATALYST OR MUFFLER HEAT SHIELDS ^ NOISE - "BUZZING" OR "RATTLING" - LOOSE CATALYST OR MUFFLER HEAT SHIELDS FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-99 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-99 CONTOUR LINCOLN-MERCURY: 1993-94 CAPRI, TOPAZ 1993-99 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 F SUPER DUTY, F-35O 1993-99 AEROSTAR, ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER, VILLAGER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES This TSB article is being republished in its entirety to include additional vehicles and to include 1999 model year vehicles. ISSUE A "buzzing" or "rattling" noise from the exhaust system may be caused by a loose heat shield attachment to the catalytic converter, catalytic pipes, muffler pipes and/or muffler. The noise is noticeable during normal driving conditions or at engine idle. ACTION Install worm clamps to secure loose heat shield attachments. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect for loose shields. If shield(s) is missing, this TSB does not apply. Refer to the appropriate Service or Workshop Manual for repair procedures NOTE UNDER NO CIRCUMSTANCES SHOULD A HEAT SHIELD BE REMOVED WITHOUT REPLACEMENT BEFORE THE VEHICLE IS RETURNED TO THE CUSTOMER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3020 2. Install worm clamps to the catalytic converter, catalytic pipes, muffler pipes or muffler as shown in Figure 1 for the typical light truck and Figure 2 for the typical passenger car. 3. Align the clamps to secure the heat shield to the catalytic converter, catalytic pipes, muffler pipes or muffler as required. 4. Tighten the clamps to 6.8 N.m (60 lb-in). 5. Trim the excess "ear" of the clamp to approximately 2.54 cm (1"). PART NUMBER PART NAME FOTZ-5A231-A Worm clamp (4-1/2" To 9-1/2") W705949-S300 Worm clamp (3/4" To 4") OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-6-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models Bumper To Bumper Warranty Coverage For 1992-99 Models, And Any Applicable Emissions Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Catalyst Shield: > 98-20-10 > Oct > 98 > Exhaust System - Buzzing/Rattling Noise > Page 3021 OPERATION DESCRIPTION TIME 982010A Install One (1), Two (2), Or 0.3 Hr. Four (4) Worm Clamps DEALER CODING CONDITION BASIC PART NO. CODE 5E258 33 OASIS CODES: 403000, 702000, 702100, 702200, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 3022 Catalyst Shield: Testing and Inspection NOTE: At idle or during normal driving conditions, a buzz or rattle may be detected, which can be traced to the exhaust system. The heat shield attachment to the muffler or catalytic converter may come free. The loose shield will vibrate off the muffler or catalytic converter and cause the buzz or rattle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalyst Shield > Component Information > Technical Service Bulletins > Page 3023 Catalyst Shield: Service and Repair Catalyst Heat Shields NOTE: The catalytic converter may have two cans. If shields on both cans are loose, four clamps (two for each) will be required. ^ Attach two band clamps to the catalytic converter or muffler as shown. Tighten to 7 Nm (60 in lb). ^ Align the clamp to secure the heat shield to the muffler or catalytic converter. Tighten the clamp to no more than 7 Nm (60 in lb). ^ Trim excess "ear" to approximately 25mm (1 inch). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation Canister Purge Solenoid: Description and Operation Fuel Vapor Canister Purge Regulator Valve PURPOSE The fuel vapor canister purge regulator valve is a normally closed valve in the evaporative emission system. It is located in the vapor line between the fuel vapor canister and throttle body. OPERATION The operation of the fuel vapor canister purge regulator valve is controlled by the powertrain control module. When the engine is off, the fuel vapor canister purge regulator valve is not energized and is in a closed, non-flowing condition. When the engine is running, the powertrain control module reads engine rpm, engine load, engine temperature and other variables, and decides the proper time for the engine to accept fuel vapors. When this occurs, the powertrain control module energizes the fuel vapor canister purge regulator valve, allowing flow from the fuel vapor canister to the intake manifold. The vapors are then consumed in the engine. This action "purges" the fuel vapor canister of fuel vapors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation > Page 3028 Canister Purge Solenoid: Service and Repair REMOVAL ^ Disconnect wire harness from fuel vapor canister purge regulator valve. ^ Disconnect fuel vapor hoses from fuel vapor canister purge regulator valve and remove fuel vapor canister purge regulator valve. INSTALLATION ^ To install, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Specifications Charcoal Canister: Specifications Clip Nut For Filter & Tube Assembly.................................................................................................... .............................................15-22 Nm (11-16 ft lb) EVAP Canister To Bracket Screw....................... ...................................................................................................................................6-9 Nm (53-80 in lb) EVAP Canister Bracket Screw........................................................................................................ ....................................................8-12 Nm (71-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Specifications > Page 3032 Vapor Lines Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Specifications > Page 3033 Charcoal Canister: Description and Operation Carbon Canisters, Typical PURPOSE Fuel vapors from the fuel tank and air cleaner assembly are stored in the carbon canister. OPERATION When the vehicle is operated, the vapors will purge from the canister into the engine for consumption. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Specifications > Page 3034 Charcoal Canister: Service and Repair REMOVAL ^ Disconnect vapor hoses from fuel vapor canister to be removed. ^ Remove screw retaining fuel vapor canister to fuel bracket or fender apron. ^ Lift fuel vapor canister to disengage tab on back side of fuel vapor canister, and remove fuel vapor canister. INSTALLATION ^ For installation, follow removal steps in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Locations Vapor Lines Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Locations > Page 3038 Evaporative Fuel Vapor Return Hose: Service and Repair REMOVAL ^ Disconnect fuel vapor front hose from crankcase ventilation tube. ^ Disconnect fuel vapor front hose from fuel vapor canister. ^ Disconnect fuel vapor front hose from fuel vapor canister purge regulator valve. INSTALLATION ^ To install, reverse removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operation Liquid Vapor Separator: Description and Operation Vapor Control Valve PURPOSE The fuel vapor valve uses a small orifice, 1.83mm (0.072 in), that allows vapors to pass into the vapor line running forward to the fuel vapor canister. OPERATION Fuel vapors trapped in the sealed fuel tank are vented through the orificed fuel vapor valve. The vapors from the fuel tank leave the fuel vapor valve through a single vapor line and continue to the fuel vapor canister in the engine compartment for storage. If, due to extreme conditions, excessive pressure is generated inside the fuel tank, the purge port opens up allowing the fuel vapor to escape to the atmosphere, and stabilizes the pressure inside the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Description and Operation EGR Vacuum Regulator Solenoid: Description and Operation EGR Vacuum Regulator (EVR) Solenoid PURPOSE The EGR Vacuum Regulator (EVR) solenoid is an electromagnetic device which controls vacuum output to the EGR valve. OPERATION The Powertrain Control Module (PCM) outputs a duty cycle to the EVR which regulates the vacuum level to the EGR valve. As the duty cycle is increased, so is the vacuum signal to the EGR valve. The vacuum source is manifold vacuum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications EGR Tube: Specifications EGR Valve Retaining Bolts .............................................................................................................................................................. 20-30 Nm (15-22 ft lb) EGR Valve To Exhaust Manifold Tube Nut .................................................................................................................................. 34-47.6 Nm (25-35 ft lb) EGR Transducer Retaining Bolt ....................................................................................................................................................... 20-30 Nm (15-22 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Specifications > Page 3049 EGR Tube: Service and Repair REMOVAL ^ Remove the EGR transducer retaining bolt and reposition the EGR transducer to access the EGR external pressure valve. ^ Disconnect the EGR valve to exhaust manifold tube at the EGR external pressure valve and exhaust manifold. ^ Disconnect hoses and remove EGR valve to exhaust manifold tube. ^ Remove EGR valve tube to manifold connector from exhaust manifold. NOTE: EGR valve to exhaust manifold tube and EGR transducer hoses must be routed behind transmission kickdown cable. INSTALLATION ^ To install, reverse removal procedure. Tighten EGR valve tube to manifold connector and EGR valve to exhaust manifold nuts to 34-48 Nm (25-35 ft lb). Tighten EGR transducer retaining bolt to 20-30 Nm (15-22 ft lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications EGR Valve Retaining Bolts .............................................................................................................................................................. 20-30 Nm (15-22 ft lb) EGR Valve To Exhaust Manifold Tube Nut .................................................................................................................................. 34-47.6 Nm (25-35 ft lb) EGR Transducer Retaining Bolt ....................................................................................................................................................... 20-30 Nm (15-22 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3053 EGR Valve Components Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3054 EGR Valve: Description and Operation Typical EGR Valve PURPOSE The Exhaust Gas Recirculation (EGR) valve is designed to reintroduce exhaust gas into the combustion cycle lowering combustion temperatures and reducing the formation of Nitrous Oxide. OPERATION The amount of exhaust gas reintroduced and the timing of the cycle varies by calibration and is controlled by factors such as engine speed, engine vacuum, exhaust system back pressure, coolant temperature and throttle angle. All EGR valves are vacuum actuated. The vacuum diagram is on the emission decal for each calibration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3055 EGR Valve: Service and Repair EGR Valve and Components REMOVAL ^ Remove the EGR transducer retaining bolt and reposition the EGR transducer to access the EGR external pressure valve. ^ Disconnect the EGR valve to exhaust manifold tube from the EGR external pressure valve. ^ Remove the EGR valve retaining bolts and the EGR external pressure valve from the upper intake manifold. ^ Remove the EGR valve gasket and clean gasket sealing surface of upper intake manifold. If the old EGR external pressure valve is to be installed, clean the gasket sealing surface. INSTALLATION ^ Position EGR external pressure valve, with a new EGR valve gasket, onto upper intake manifold and install retaining bolts. Tighten retaining bolts to 20-30 Nm (15-22 ft lb). ^ Connect the EGR valve to exhaust manifold tube to the EGR external pressure valve. Tighten EGR valve to exhaust manifold tube nut to 34-47.6 Nm (25-35 ft lb). ^ Install the EGR transducer and retaining bolt. Tighten retaining bolt to 20-30 Nm (15-22 ft lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3060 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3061 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Check Valve, EGR > Component Information > Description and Operation Vacuum Check Valve: Description and Operation Vacuum Check Valve PURPOSE The vacuum check valve blocks airflow in one direction and allows free airflow in the other direction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Check Valve, EGR > Component Information > Description and Operation > Page 3065 Vacuum Check Valve: Testing and Inspection Vacuum Check Valve Apply 54 kPa (16 in Hg) vacuum to "check" side of the valve and trap. If vacuum remains above 50 kPa (15 in Hg) for 10 seconds, the valve is acceptable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Reservoir, EGR > Component Information > Description and Operation Vacuum Reservoir: Description and Operation PURPOSE The vacuum reservoir stores vacuum and provides "muscle" vacuum. It prevents rapid fluctuations or sudden drops in a vacuum signal such as those seen during an acceleration period. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Vacuum Reservoir, EGR > Component Information > Description and Operation > Page 3069 Vacuum Reservoir: Testing and Inspection DIAGNOSIS When charged initially with 51-67 kPa (15-20 in Hg) vacuum, vacuum loss shall not exceed 2 kPa (.5 in Hg) in 60 seconds. If it does, replace the reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fillpipe Restrictor PURPOSE The restricted opening of the fuel tank filler pipe allows only an unleaded fuel nozzle to be inserted. CONSTRUCTION The restrictor consists of a narrow opening in the fuel tank filler pipe covered by a spring steel flap. OPERATION The smaller unleaded fuel nozzle will fit through the narrow opening and push the trap door aside, allowing normal filling. Leaded fuel nozzles will not fit in the narrow opening. The spring steel flap being closed causes a fuel back-up and automatic nozzle shut-off. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation Positive Crankcase Ventilation Valve: Description and Operation Typical PCV Valve PURPOSE The PCV valve regulates the amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase. NOTE: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect fuel economy and engine ventilation resulting in shorter engine life. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 3077 Positive Crankcase Ventilation Valve: Service and Repair CLEANING ^ Cleaning of the positive crankcase ventilation valve is not recommended. ^ The positive crankcase ventilation valve should be replaced if needed. INSPECTION ^ Shake positive crankcase ventilation valve and carefully inspect for splits or cracks. ^ If positive crankcase ventilation valve does not rattle or is damaged, replace positive crankcase ventilation valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision Pressure Feedback Exhaust Sensor: Technical Service Bulletins EGR DPFE Sensor - Voltage Range Revision Article No. 97-22-1 10/27/97 DELTA PRESSURE FEEDBACK EGR (DPFE) - DIAGNOSTIC TIPS FORD: 1994-97 MUSTANG, THUNDERBIRD 1995-97 CONTOUR, CROWN VICTORIA 1996-97 ESCORT, TAURUS LINCOLN-MERCURY: 1990-97 TOWN CAR 1994-97 COUGAR 1995-97 CONTINENTAL, GRAND MARQUIS, MYSTIQUE 1996-97 SABLE, TRACER LIGHT TRUCK: 1994-97 EXPLORER 1995-97 ECONOLINE, F-150-350 SERIES, WINDSTAR 1996-97 AEROSTAR 1997 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: The current DPFE sensor diagnostic reference values as published in the Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual, and also accessed by either the Service Bay Diagnostic System (SBDS) or Service Bay Technical System (SBTS), can lead to the replacement of good DPFE sensors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > EGR DPFE Sensor - Voltage Range Revision > Page 3083 ACTION: Use the following revised DPFE sensor voltage ranges for all (black plastic or aluminum) DPFE system applications when checking the PID (Parameter Identifier Display) value "DPFEGR" or when measuring the DPFE sensor input directly at the breakout box. Refer to Figure 1. NOTE: THESE LISTED VOLTAGE RANGES SHOULD BE USED FOR ALL (BLACK PLASTIC OR ALUMINUM) DPFE SYSTEM APPLICATIONS WHENEVER CHECKING THE PID VALUE "DPFEGR" OR WHEN MEASURING THE DPFE SENSOR INPUT DIRECTLY AT THE BREAKOUT BOX. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 3084 Pressure Feedback Exhaust Sensor: Description and Operation Differential Pressure Feedback EGR (DPFE) Sensor PURPOSE The Differential Pressure Feedback (DPFE) EGR sensor converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the Powertrain Control Module (PCM). OPERATION The PCM uses the signal received from the DPFE sensor to compute the optimum EGR flow. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Locations Air Intake System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Locations > Page 3088 Inlet Air Temperature Control: Description and Operation Air Intake System Air intake system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Locations > Page 3089 TAC Vacuum Motor And Duct Valve Vacuum motor. PURPOSE Fresh air or heated air from a engine air cleaner duct shroud and tube around the exhaust manifold is made available to the engine air intake through a system of ducting. The vacuum-operated duct system can select either warm air from shrouding around the exhaust manifold or cool air from an outside air pickup tube. Selection is made by a temperature-sensitive vacuum system that operates the duct valve. OPERATION When the engine is cold, air is selected from the exhaust manifold engine air cleaner duct shroud and tube because the temperature sensor in the engine air cleaner is cold and vacuum is applied to the vacuum motor that operates the duct valve. As the engine warms, heated air enters the engine air cleaner and warms the sensor. The sensor then limits the amount of vacuum applied to the vacuum motor. This closes the duct valve and allows pickup of cooler ambient air from the outside air pickup tube. LOCATION The remote duct and valve assembly is located under the battery tray and has a bimetal switch located in the air-cleaner cover. The vacuum motor is located on the duct and valve assembly. The Intake Air Temperature (IAT) sensor is located in the engine air cleaner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis Flow Of Diagnosis -- Emission Control Systems Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3092 Inlet Air Temperature Control: Symptom Related Diagnostic Procedures Hesitates or Stalls on Acceleration CONDITION ^ Hesitates or stalls on acceleration. ACTION ^ Go to pinpoint test step AIS 1. See: Pinpoint Tests/AIS 1 Preliminary Checks - Hesitation/Stalls on Acceleration Lack of Power CONDITION ^ Lack of power. ACTION ^ Go to pinpoint test step AIS 2. See: Pinpoint Tests/AIS 2 Preliminary Checks For Lack Of Power Spark Knock CONDITION ^ Spark knock. ACTION ^ Go to pinpoint test step AIS 4. See: Pinpoint Tests/AIS 4 Vacuum Motor Check Poor Fuel Economy CONDITION ^ Poor fuel economy. ACTION ^ Go to pinpoint test step AIS 3. See: Pinpoint Tests/AIS 3 Preliminary Checks For Poor Fuel Economy Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3093 Inlet Air Temperature Control: Pinpoint Tests AIS 1 Preliminary Checks - Hesitation/Stalls on Acceleration ^ Key OFF, engine OFF. ^ Check that throttle lever is resting on throttle plate stop screw. ^ Key ON, engine RUNNING. ^ Check engine operating temperature and coolant level in overflow reservoir. ^ Check for vacuum leak At intake manifold and hose routings. ^ Check for proper operation of EGR valve. ^ Check for ignition or exhaust malfunction. ^ Check fuel quality (contamination). ^ Are any problems found? YES -- Service or adjust as necessary. Replace parts as necessary. NO -- Go to AIS 4. See: AIS 4 Vacuum Motor Check AIS 2 Preliminary Checks For Lack Of Power ^ Key ON, engine OFF. ^ Check proper belt tension. ^ Check for throttle linkage binding. ^ Key ON, engine RUNNING. ^ Check engine operating temperature and coolant level in overflow reservoir. ^ Check for vacuum leak at intake manifold and hose routings. ^ Check for proper operation of EGR valve. ^ Check for ignition or exhaust malfunction (refer to maintenance schedule). ^ Check for brake drag. ^ Check transmission shift schedule. ^ Are any problems found? YES -- Service or adjust as necessary. Replace parts as necessary. NO -- Go to AIS 4. See: AIS 4 Vacuum Motor Check AIS 3 Preliminary Checks For Poor Fuel Economy ^ Key OFF, engine OFF. ^ Check for contaminated Idle Air Control (IAC) valve or proper sealing around valve. ^ Check PCV system (incorrect specifications or clogged). ^ Key ON, engine RUNNING. ^ Check engine operating temperature and coolant level in overflow reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3094 ^ Check for ignition or exhaust malfunction (refer to maintenance schedule). ^ Are any problems found? YES -- Service or adjust as necessary. Replace parts as necessary. NO -- Go to AIS 4. See: AIS 4 Vacuum Motor Check AIS 4 Vacuum Motor Check TAC Vacuum Motor ^ Check vacuum motor for proper function. ^ When a vacuum of 27 kPa (8 in Hg) or greater is applied to the vacuum motor, does the stem pull up and stay as long as the vacuum is applied? YES -- Go to AIS 5. See: AIS 5 Duct And Valve Check NO -- Replace vacuum motor. AIS 5 Duct And Valve Check Duct And Valve ^ Check duct and valve for proper function. ^ When vacuum of 27 kPa (8 in Hg) or greater is applied to the vacuum motor, the door should go to the full heat position. When the hose is then disconnected, the door should go to the fresh air position. ^ Does this occur? YES -- Go to AIS 6. See: AIS 6 Bimetal Sensor Check NO -- Replace the duct and valve assembly. AIS 6 Bimetal Sensor Check Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3095 Bimetal Sensor ^ Check the bimetal sensor. ^ Bring the temperature of the bimetal sensor below 24°C (75°F) and apply 54 kPa (16 in Hg) vacuum. ^ Does the door close (go to the hot air position)? YES -- Go to AIS 7. See: AIS 7 Air Filter Check NO -- Replace bimetal sensor. AIS 7 Air Filter Check ^ Check the air filter. ^ Is the air filter excessively dirty? YES -- Replace air filter. NO -- Go to AIS 8. See: AIS 8 Sealing Integrity AIS 8 Sealing Integrity ^ Check hoses that connect air cleaner to engine. ^ Are there cracks or leaks? ^ Are there any cracks in the air cleaner assembly? ^ Check the air filter for proper sealing. ^ Are there any leaks around the air filter seal? YES -- Replace parts as required. NO -- Go to AIS 9. See: AIS 9 Check Torque AIS 9 Check Torque ^ Check clamps and air cleaner screws (if equipped) for proper torque. ^ Is torque correct? YES -- Go to AIS 10. See: AIS 10 Check Idle Speed NO -- Tighten to specification. AIS 10 Check Idle Speed ^ Check idle speed to specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Component Information > Testing and Inspection > Flow of Diagnosis > Page 3096 ^ Is idle speed correct? YES -- Air intake system is functioning properly. Return to system flow charts. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Flow of Diagnosis NO -- Adjust idle speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 3102 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3106 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3107 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments Idle Speed: Adjustments NOTE: Curb and fast idle speeds are controlled by the Powertrain Control Module (PCM) and Idle Air Control (IAC) valve assembly. The IAC valve and idle speed is not adjustable. A large increase or decrease in closed plate airflow from the calibrated level will not allow effective idle speed control. Throttle Body Assembly Throttle bodies with sludge tolerant design are identified with a yellow/black decal. The throttle body must not be cleaned inside the bore, as this cleaning will impair the sensitive coating. Sludge accumulation will not affect the idle air flow. The cleaning procedure for the IAC valve still applies. RPM LIMIT CHECK PROCEDURE - Self-Test constant tone STAR tester or equivalent scanner required 1. Activate engine running Self-Test. 2. After diagnostic trouble code 11 or 111 has been displayed, unlatch and within 4 seconds latch the Self-Test Input (STI) button. 3. A single pulse code indicates the entry mode, then observe the Self-Test Output (STO) of the STAR tester. - A constant tone, solid light or "STO LO" readout indicates base idle rpm is within range. - Beeping tone, flashing light, or STO LO readout at 8.0 Hz indicates Throttle Position (TP) is out of range due to over adjustment. - Beeping tone, flashing light, or STO LO readout at 4.0 Hz indicates base idle rpm is too fast. - Beeping tone, flashing light, or STO LO readout at 1.0 Hz indicates base idle is too slow. 4. To exit test, unlatch STI button, then wait 4 seconds for reinitialization (after 10 minutes it will exit by itself). 5. If the idle rpm (engine warm, in Neutral, A/C "Off") is not within limits, refer to Testing and Inspection / Procedures / Air Induction Diagnosis for other possible causes of idle problem. See: Testing and Inspection/Pinpoint Tests/AIS - Air Induction Diagnosis Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > Adjustments Air/Fuel Mixture: Adjustments Air/fuel mixture requirement is computer controlled and not adjustable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal: > 00-24-3 > Nov > 00 > Accelerator Pedal Bracket - Cracks or Fatigues Accelerator Pedal: Customer Interest Accelerator Pedal Bracket - Cracks or Fatigues Article No. 00-24-3 11/27/00 ACCELERATOR PEDAL BRACKET - SHEET METAL CRACKS OR FATIGUES AT DASH PANE AREA - ALL MODELS - VEHICLES BUILT 9/1/1990 THROUGH 7/1/1999 FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER ISSUE The accelerator pedal bracket may become loose or separated from the dash panel on some vehicles. This may be caused by repeated excessive force on the accelerator pedal, resulting in cracking of the dash panel sheet metal at the accelerator pedal bracket. ACTION Repair loose or separated accelerator bracket and/or crack at dash panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to Figure 1 illustration throughout Service Procedure. 1. Remove accelerator pedal pivot bolt and pedal from bracket. 2. With bracket placed in original position on dash panel, use the two (2) holes in base of bracket as pilots, and drill two (2) holes in dash panel using a 9 mm (11/32") drill. 3. Examine dash panel on engine side for any cracks related to the attachment failure. If cracks are present, clean the surface with a suitable solvent and apply sealant to the cracks, such as RTV Sealant (F5TZ-19G204-AB). 4. Apply same sealant on the underside of the head flanges and all around the shanks of two (2) M8 x 16 hex flange Bolts (W500022-S309). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Customer Interest for Accelerator Pedal: > 00-24-3 > Nov > 00 > Accelerator Pedal Bracket - Cracks or Fatigues > Page 3125 5. From inside the vehicle, with bracket held in original position, insert bolts through holes in bracket and dash panel. 6. On engine side of dash panel, assemble on (1) Flatwasher (391982-S191) (7/16" ID x 1.0" OD), and one (1) M8 prevailing torque hex flange Nut (W520112-S309) on each of the bolts. Tighten nuts to a torque of 27-33 Nm (20-24 lb-ft). 7. Replace pedal and pivot bolt and tighten pivot bolt to a torque of 9-12 Nm (80-108 lb-in). 8. Check accelerator pedal for proper operation. PART INFORMATION OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Cover OPERATION DESCRIPTION TIME 002403A Repair Of Accelerator 0.6 Pedal Bracket DEALER CODING OASIS CODES: 111000, 404000, 614500 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > 00-24-3 > Nov > 00 > Accelerator Pedal Bracket - Cracks or Fatigues Accelerator Pedal: All Technical Service Bulletins Accelerator Pedal Bracket - Cracks or Fatigues Article No. 00-24-3 11/27/00 ACCELERATOR PEDAL BRACKET - SHEET METAL CRACKS OR FATIGUES AT DASH PANE AREA - ALL MODELS - VEHICLES BUILT 9/1/1990 THROUGH 7/1/1999 FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER ISSUE The accelerator pedal bracket may become loose or separated from the dash panel on some vehicles. This may be caused by repeated excessive force on the accelerator pedal, resulting in cracking of the dash panel sheet metal at the accelerator pedal bracket. ACTION Repair loose or separated accelerator bracket and/or crack at dash panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE Refer to Figure 1 illustration throughout Service Procedure. 1. Remove accelerator pedal pivot bolt and pedal from bracket. 2. With bracket placed in original position on dash panel, use the two (2) holes in base of bracket as pilots, and drill two (2) holes in dash panel using a 9 mm (11/32") drill. 3. Examine dash panel on engine side for any cracks related to the attachment failure. If cracks are present, clean the surface with a suitable solvent and apply sealant to the cracks, such as RTV Sealant (F5TZ-19G204-AB). 4. Apply same sealant on the underside of the head flanges and all around the shanks of two (2) M8 x 16 hex flange Bolts (W500022-S309). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > 00-24-3 > Nov > 00 > Accelerator Pedal Bracket - Cracks or Fatigues > Page 3131 5. From inside the vehicle, with bracket held in original position, insert bolts through holes in bracket and dash panel. 6. On engine side of dash panel, assemble on (1) Flatwasher (391982-S191) (7/16" ID x 1.0" OD), and one (1) M8 prevailing torque hex flange Nut (W520112-S309) on each of the bolts. Tighten nuts to a torque of 27-33 Nm (20-24 lb-ft). 7. Replace pedal and pivot bolt and tighten pivot bolt to a torque of 9-12 Nm (80-108 lb-in). 8. Check accelerator pedal for proper operation. PART INFORMATION OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Cover OPERATION DESCRIPTION TIME 002403A Repair Of Accelerator 0.6 Pedal Bracket DEALER CODING OASIS CODES: 111000, 404000, 614500 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Technical Service Bulletins > Page 3132 Accelerator Pedal: Specifications Accelerator Pedal Pivot Screw ....................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Accelerator Pedal: Symptom Related Diagnostic Procedures Accelerator Pedal Is Hard to Push Down CONDITION - Accelerator pedal is hard to push down or has a rough, raspy or sticky feel. POSSIBLE SOURCE - Full pedal travel is restricted. - Worn or damaged cable. - Restricted pedal operation. ACTION - Go to Test A. See: Pinpoint Tests/Test A High Engine Idle Speed CONDITION - High engine idle speed. POSSIBLE SOURCE - Cable ball socket extends beyond the throttle lever ball stud when cable is disconnected from throttle lever. - Restricted foot pedal operation. - Worn or damaged cable. - Refer to the throttle body diagnosis procedure. - Adjust carpet, floor mat or wiring as required. ACTION - Go to Test C. See: Pinpoint Tests/Test C Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3135 Accelerator Pedal: Pinpoint Tests Test A ^ Disconnect the cable end from the throttle body linkage. ^ Ensure the disconnected end of cable does not come in contact the with any of the surrounding parts. ^ Operate the pedal by hand. ^ Is the full pedal travel to WOT restricted by carpeting, floor mats, etc.? YES -- Remove restriction to pedal travel. NO -- Go to Test B. See: Test B Test B ^ Cable end should remain disconnected. ^ Operate the pedal by foot. ^ Is the pedal operation smooth? NOTE: The accelerator cable should not be lubricated and is not a serviceable item. YES -- Refer to the throttle body diagnosis procedures. NO -- Check the foot pedal assembly for free operation or check for worn or damaged cable by following Test C. See: Test C Test C ^ Disconnect the cable from the ball stud at the throttle body. ^ Ensure the disconnected end of the cable does not come in contact with any of the surrounding parts. ^ From inside the vehicle, pull the cable core wire through its full travel. - Does it feel rough, sticky or restricted? ^ Release the core wire. - Does it stick or hesitate before returning to its original position? ^ Compress the spring at the throttle body end of the cable and observe the cable as it returns to its original position. ^ Does the spring stick or fail to return to its original position at a rapid rate? YES -- If Yes to any of the questions: Replace the cable. NO -- If No to all of the questions: Cable is functioning properly. Refer to the Throttle Body / Testing and Inspection / Procedures or adjust the carpet, floor mat, etc., as required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 3136 Accelerator Pedal: Service and Repair Accelerator Pedal Assembly REMOVAL 1. Disconnect accelerator cable from accelerator pedal assembly. 2. Disconnect kickdown cable from accelerator pedal assembly, if equipped. 3. Remove bolt attaching accelerator pedal assembly to dash panel and remove accelerator pedal assembly. INSTALLATION 1. Position accelerator pedal assembly to dash panel and install attaching bolt. Tighten to 9-12 Nm (80-106 in lb). 2. Connect accelerator cable and kickdown cable to accelerator pedal assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Engine - Water Entry Through Air Intake System Air Cleaner Fresh Air Duct/Hose: Technical Service Bulletins Engine - Water Entry Through Air Intake System Article No. 94-3-8 02/09/94 ^ AIR INTAKE - 2.9L, 3.0L, 4.0L EFI ENGINES - WATER ENTRY THROUGH AIR INTAKE SYSTEM ^ ENGINE - 2.9L, 3.0L, 4.0L EFI - POSSIBLE INTERNAL DAMAGE FROM WATER ENTRY THROUGH AIR INTAKE SYSTEM LIGHT TRUCK: 1986-90 BRONCO II 1986-94 RANGER 1991-94 EXPLORER This article is being republished in its entirety to add 1993-94 4.0L Ranger, 1993-94 3.0L Ranger and 1993-94 4.0L Explorer vehicles. ISSUE: Reports have been received of internal engine damage caused by water entering the engine through the air intake system. This condition may occur when the vehicle is driven in normal wet conditions, such as water splash/spray from other vehicles, or when driven through shallow water. Improvements were made to the EFI engine air intake systems that have greatly reduced the number of reported incidences. ACTION: Dealers should be assured that warranty repairs will be covered unless there Is evidence of owner misuse. This warranty repair policy will remain effective unless you are notified that a waterproof air intake system has been released. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-21-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Technical Service Bulletins > Page 3142 Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL NOTE: The heat supply plenum door actuating motor and hose are not serviceable items. Repair requires the replacement of the engine air cleaner intake tube and duct. 1. Remove engine air cleaner. 2. Remove heat supply hose from exhaust manifold engine air cleaner duct shroud and tube and engine air cleaner intake tube and duct. 3. Remove one retaining screw from radiator support (baffle). 4. Remove actuator motor vacuum supply hose from bi-metal sensor in engine air cleaner assembly upper cover. 5. Remove engine air cleaner intake tube and duct from vehicle. INSTALLATION 1. Position engine air cleaner intake tube and duct and install retaining screw. 2. Reassemble engine air cleaner as described in this section. 3. Connect engine air cleaner intake tube and duct to engine air cleaner. Make sure engine air cleaner intake tube and duct snaps into place. 4. Connect vacuum hose to bi-metal sensor. 5. Install heat supply hose assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation Air Cleaner Element: Description and Operation PURPOSE Filters out unwanted dust, dirt and debris. CONSTRUCTION Chemically-treated, pleated paper element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 3146 Air Cleaner Element: Service and Repair Air Intake System REMOVAL 1. Loosen outlet tube clamps from air cleaner cover and throttle body. Remove the outlet tube. 2. Disconnect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 3. Disconnect the Mass Air Flow (MAF) sensor electrical connection. 4. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 5. Remove the two air cleaner cover retaining screws, then the air cleaner cover. 6. Remove the air filter element. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Element <--> [Air Filter Element] > Component Information > Description and Operation > Page 3147 INSTALLATION 1. Install the air filter element. 2. Remove the air cleaner cover, then the two air cleaner cover retaining screws. Tighten the screws to 3 Nm (26 lb in). 3. Connect the IAT sensor electrical connector. 4. Connect the MAF sensor electrical connection. 5. Connect the vacuum tubes to bi-metallic sensor in the air cleaner cover. 6. Install the outlet tube. Tighten the outlet tube clamps at the air cleaner cover and throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3156 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3157 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3163 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3164 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3169 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3175 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 3178 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3179 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3180 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3181 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3182 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 3186 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component Information > Description and Operation Fillpipe Restrictor: Description and Operation Fillpipe Restrictor PURPOSE The restricted opening of the fuel tank filler pipe allows only an unleaded fuel nozzle to be inserted. CONSTRUCTION The restrictor consists of a narrow opening in the fuel tank filler pipe covered by a spring steel flap. OPERATION The smaller unleaded fuel nozzle will fit through the narrow opening and push the trap door aside, allowing normal filling. Leaded fuel nozzles will not fit in the narrow opening. The spring steel flap being closed causes a fuel back-up and automatic nozzle shut-off. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 01-19-7 > Oct > 01 > Engine - Carbon Knock On Acceleration Fuel: Customer Interest Engine - Carbon Knock On Acceleration Article No: 01-19-7 10/01/01 ^ ENGINE - 4.0L OHV - CARBON KNOCK ON ACCELERATION ^ NOISE - CARBON KNOCK ON ACCELERATION - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Use Motorcraft Carburetor Tune-up Cleaner PM-3. 2. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter. 3. Review the customers' driving habits. The recommended drive cycle should include daily periods of engine operation above 3,000 RPM, such as a brisk acceleration from a stop position. This will break/burn the carbon off the piston head. 4. Use regular unleaded fuel, 87 Octane. Mid-grade and Premium fuels may increase the probability of carbon buildup, leading to a knock noise. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011907A Remove Carbon From 1.6 Hrs. Combustion Chamber (Includes Time To Perform Procedure A Total Of Three Times) DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 01-19-7 > Oct > 01 > Engine - Carbon Knock On Acceleration > Page 3198 BASIC PART NO. CODE 6108 42 OASIS CODES: 497000, 615000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 01-19-7 > Oct > 01 > Engine - Carbon Knock On Acceleration Fuel: All Technical Service Bulletins Engine - Carbon Knock On Acceleration Article No: 01-19-7 10/01/01 ^ ENGINE - 4.0L OHV - CARBON KNOCK ON ACCELERATION ^ NOISE - CARBON KNOCK ON ACCELERATION - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Use Motorcraft Carburetor Tune-up Cleaner PM-3. 2. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter. 3. Review the customers' driving habits. The recommended drive cycle should include daily periods of engine operation above 3,000 RPM, such as a brisk acceleration from a stop position. This will break/burn the carbon off the piston head. 4. Use regular unleaded fuel, 87 Octane. Mid-grade and Premium fuels may increase the probability of carbon buildup, leading to a knock noise. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011907A Remove Carbon From 1.6 Hrs. Combustion Chamber (Includes Time To Perform Procedure A Total Of Three Times) DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 01-19-7 > Oct > 01 > Engine - Carbon Knock On Acceleration > Page 3204 BASIC PART NO. CODE 6108 42 OASIS CODES: 497000, 615000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns Fuel: All Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 3209 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3214 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3215 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns Fuel: All Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 3221 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3226 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3227 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3228 Fuel: Testing and Inspection PREPARATION Obtain a fuel sample from the bottom of the fuel tank so that any water present will be detected. The sample should be bright and clear. If the sample appears cloudy or contaminated with water (indicated by a layer at the bottom of the sample), this procedure should not be used and fuel system should be cleaned. TESTING 1. Fill a 100 ml cylinder with 1 ml graduation marks to the 90 ml mark. 2. Add 10 ml of water to bring the total fluid volume to 100 ml. Install a stopper. 3. Shake vigorously for 10 to 15 seconds. 4. Loosen stopper to release pressure. 5. Close stopper and repeat shaking for 10 to 15 seconds. 6. Place the cylinder on a level surface for approximately 5 minutes to allow adequate liquid separation. RESULTS EVALUATION If alcohol is present, the volume of the lower layer (now containing both alcohol and water) will be greater than 10 ml. For example, if lower layer volume is increased to 15 ml, it indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat greater because this procedure does not extract all alcohol from fuel. Allowable Alcohol/Fuel Concentration Alcohol/Fuel Type % by Volume Methanol (Wood Alcohol) 5.0% Ethanol (Grain Alcohol) 10.0% MTBE (Methyl Tertiary Butyl Ether) 15.0% Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Specifications Fuel Filler Cap: Specifications Vacuum Relief Valve Opens ................................................................................................................ ................................................... -3.4 kPa (-0.5 psi) Pressure Relief Valve Opens .................................................................................................................................................... 11.1-14.4 kPa (1.6-2.1 psi) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Service Precautions > Customer Safety Information Fuel Filler Cap: Customer Safety Information CAUTION Fuel tank may be pressurized. To relieve pressure, rotate fuel cap over one half turn counterclockwise. If fuel cap is venting fuel or a hissing sound is heard, wait until condition stops before continuing to turn cap if these precautions are not followed, fuel may spray and cause personal injury. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Service Precautions > Customer Safety Information > Page 3234 Fuel Filler Cap: Technician Safety Information CAUTION - Fuel tank may be pressurized. To relieve pressure, rotate fuel cap over one half turn counterclockwise. If fuel cap is venting fuel or a hissing sound is heard, wait until condition stops before continuing to turn cap if these precautions are not followed, fuel may spray and cause personal injury. - Do not smoke, carry lighted tobacco or an 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. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Service Precautions > Page 3235 Fuel Filler Cap: Description and Operation Fuel Tank Pressure/Vacuum Filler Cap PURPOSE Provides slight pressure on the fuel reducing the evaporation rate and vacuum relief functions that allows the tank to vent. OPERATION Under normal operating conditions, the fill cap operates as a check valve preventing vapors from escaping the tank through the cap. Fuel system vacuum relief is provided after approximately -3.4 kPa (-0.5 psi) is reached inside the tank. Pressure relief is provided when pressure inside the tank builds up approximately 11.1-14.4 kPa (1.6-2.1 psi). CONSTRUCTION The threaded screw-on design cap incorporates an integral pressure-vacuum relief valve. The fuel tank filler cap is a threaded screw-on with a pre-vent feature that allows the fuel tank to vent for the first three-quarter turn before unthreading. The fuel tank filler cap is fitted with a torque-limiting ratchet to prevent difficulty in removal. When installing the fuel tank filler cap, continue to turn clockwise until ratchet mechanism gives off three or more loud clicks. Fuel tank filler caps are attached to the vehicle with a tether using the fuel tank filler pipe-to-housing screw. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair CAUTION: Fuel supply lines on all vehicles equipped with fuel injected engines will remain pressurized after the engine is shut Off. FUEL PRESSURE GAUGE METHOD 1. Disconnect negative battery cable from the battery. 2. Remove fuel tank cap. 3. Remove cap from schrader valve on fuel supply manifold, and attach EFI pressure gauge. 4. Direct gauge drain hose into approved fuel storage container, and depress pressure release button on fuel pressure gauge to bleed off fuel pressure. INERTIA FUEL SHUTOFF SWITCH DISCONNECT METHOD 1. Remove fuel tank cap. 2. Disconnect the electrical connector from the inertia fuel shutoff switch. 3. Crank engine for at least 15 to 20 seconds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Description and Operation Fuel Injector Wiring Harness: Description and Operation PURPOSE Connects the engine wire harness to each fuel injector or other electronic engine controls such as throttle position sensor and idle air control valve. OPERATION Receives fuel injector signals from the powertrain control module and transfers the signals to the fuel injectors. Signals from the powertrain control module determine the fuel injection sequence and duration each fuel injector will stay open to allow fuel into the combustion chambers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Description and Operation > Page 3244 Fuel Injector Wiring Harness: Service and Repair REMOVAL NOTE: Make sure ignition switch is in OFF position and fuel system is depressurized. 1. Disconnect electrical connectors from fuel injector nozzle tips. 2. Disconnect connectors from main wiring harness and throttle position sensor, intake air temperature sensor and idle air control valve. 3. Remove wiring assembly. INSTALLATION 1. Position wiring harness alongside fuel injector nozzle tips. 2. Snap electrical connectors into position on fuel injector nozzle tips. 3. Connect throttle position sensor, intake air temperature sensor, idle air control valve and main harness connectors. 4. Verify that all electrical connectors are firmly seated. 5. Use EEC self-test connector and procedure to check for sensor function. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Duck Bill Connector Duckbill Clip Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Duck Bill Connector > Page 3249 Hair Pin Clip Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Duck Bill Connector > Page 3250 Fuel Line Coupler: Description and Operation Spring Lock Coupler Push Connect Fittings PURPOSE Spring lock couplers are used to connect fuel lines to fuel injection supply manifolds. CONSTRUCTION The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage thus prevents the flared end of the female fitting from pulling out of the cage. As a redundant locking feature, a horseshoe shaped retaining clip is incorporated to improve the retaining reliability of the spring lock coupling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Duck Bill Connector > Page 3251 Push Connector - Steel Line Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector Fuel Line Coupler: Service and Repair Duck Bill Connector REMOVAL Duckbill Clip Connector 1. To remove duckbill, use special tool shown, or pliers with thin jaws, to release the clip. 2. Pull the connector apart gently. INSTALLATION Duck Bill Clip 1. Install fitting onto tube and push fitting onto tube end until a "click" is heard. 2. Pull on fitting to ensure it is fully engaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3254 Fuel Line Coupler: Service and Repair Hair Pin Connector NOTE: Disconnect all push connect fittings from components (sender, fuel filter and base) prior to component removal. The push connect fittings that connect flexible fuel lines to the fuel tank sender cannot be disconnected until the fuel tank is partially lowered just before removing the fuel tank completely. REMOVAL 1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly. NOTE: On 90-degree elbow connectors, excessive side loading could break the connector body. 2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube. CAUTION: Do not use any tools. 3. Remove hairpin-type clip from fitting by first bending and breaking the shipping tab. Next, (using hands only) spread the two clip legs about 3.2mm (1/8 inch) each to disengage the body and push the legs into the fitting. Complete removal is accomplished by lightly pulling from the triangular end of the clip and working it clear of the tube and fitting. 4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube. 5. After disassembly, inspect and clean tube end sealing surface. Tube end should be free of scratches and corrosion as they result in a path for fuel leakage. Inspect inside of fitting for any internal parts such as O~ring and spacer that may have been dislodged from the fitting. Replace damaged connector; do not repair it. INSTALLATION 1. Install a new connector hose assembly if connector was found to be damaged. To install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs of hairpin clip locked on outside of body). Piloting with an index finger is necessary. 2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to ensure it is free of dirt and/or obstructions. 3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged. a definite click will be heard. Pull on fitting to ensure it is fully engaged. Apply a light coat of engine oil to the tube end to ease assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3255 Fuel Line Coupler: Service and Repair Spring Lock Coupler REMOVAL 1. Relieve the fuel system pressure. CAUTION: Do not use any sharp tool or screwdriver as it may damage the spring lock coupling. Fuel Tube Clip 2. Remove the fuel tube clip from the spring lock coupling by hand. 3. Twist the fitting to free it from any adhesion at the O-ring seals. 4. Fit Disconnect Tool D87L-9280-A (3/8 inch) or D87L-9280-B (1/2 inch) or equivalent to the coupling. Disconnect Tool 5. Close the tool and push it into the open side of the cage to expand the garter spring and release the female fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3256 6. After the garter spring is expanded, pull the fittings apart. 7. Remove the tool from the disconnected coupling. INSTALLATION Spring Lock Coupler 1. Be sure the garter spring is in the cage of the male fitting. if the garter spring is missing, install a new spring by pushing it into the cage opening. If the garter spring is damaged, remove it from the cage with a small wire hook (do not use a screwdriver) and install a new spring. NOTE: Replacement garter springs: E1ZZ-19E576-A (3/8 inch) E1ZZ-19E576-B (1/2 inch) 2. Clean all dirt or foreign material from both pieces of the coupling. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3257 Fuel Tube Coupling 3. Replace the missing or damaged O-rings. Use only the O-rings listed in the illustration. Lubricate the male fitting, the O-rings and the inside of the female fitting with clean engine oil meeting Ford specification ESE-M2C39-F such as Motorcraft oil, or equivalent. CAUTION: Use only the specified O-rings as they are made of a special material. The use of any O-rings other than the specified O-rings may cause the connection to leak intermittently during vehicle operation. 4. Fit the female fitting to the male fitting and push until the garter spring snaps over the flared end of the female fitting. Garter Spring 5. Ensure coupling engagement by pulling on the fitting and visually checking it to be sure the garter spring is over the flared end of the female fitting. NOTE: All vehicles require the large "black" clip to be installed on the supply side fuel line and the small "gray" clip to be installed on the return side fuel line. Fuel Tube Clip Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3258 Fuel Tube Clip 6. Position the fuel tube clip over the metal portion of the spring lock coupling. Firmly push the fuel tube clip onto the spring lock coupling. Be sure that the horseshoe portion of the clip is over the coupling. Do not install the fuel tube clip over rubber fuel lines. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Duck Bill Connector > Page 3259 Fuel Line Coupler: Service and Repair Steel Push Connect This fitting consists of a body, spacers, O-rings and a retaining clip. The clip locks the fitting to its mating tube juncture. The following methods are to be followed to disconnect the fitting: SET-UP STEPS: 1. Inspect visible internal portion of fitting for dirt accumulation. If more than a light coating of dust is present clean the fitting before disassembly. NOTE: If necessary, drain fuel tank. 2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube. REMOVAL 1. To disengage the tube from the fitting, snap the Fuel Line Disconnect Tool T90T-9550-B 5/16 inch (Gray) and T90T-9550-C 3/8 inch (Blue) or equivalent with either tab on the fuel line-to be disconnected. 2. Push the disconnect tool into the connector to release the internal locking fingers. NOTE: Only moderate effort is required if the tube has been properly disengaged. Use hands only. 3. Separate fuel line from the connector. Remove disconnect tool. 4. After disassembly inspect and clean the tube end sealing surface. Tube end should be free of scratches and corrosion as they result in path for fuel leakage. Inspect the inside of the fitting for any internal parts such as O-rings and spacers that may have been dislodged from the fitting. Replace any damaged connector. NOTE: Some fuel tubes have a secondary bead which aligns with the outer surface of the clip. These beads can make tool insertion difficult. INSTALLATION 1. Install new connector/hose tube assembly if damage was found. 2. Before installing fitting on the tube, wipe tube end with a clean cloth. Inspect the inside of the fitting to ensure it is free of dirt and/or obstructions. 3. To install the fitting onto the tube, align the fitting and tube axially and push the fitting onto the tube end. When the fitting is engaged, a definite click will be heard. Pull on fitting to ensure it is fully engaged. Applying a light coat of engine oil to the tube end will ease assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Check Valve > Component Information > Locations Fuel Pressure Check Valve: Locations LOCATION Mounted on the In-Tank Fuel Pump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Check Valve > Component Information > Locations > Page 3263 Fuel Pressure Check Valve: Description and Operation PURPOSE Maintains fuel pump prime and fuel supply line pressure after engine is shut down. OPERATION The check valve, normally closed, opens when the outlet pressure from the energized pump exceeding the opposing check valve spring force. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications Fuel Pressure Regulator: Specifications Fuel Pressure Regulator Screws ................................................................................................................................................... 8.0-11 Nm (70-97 lb in) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3267 Fuel Pressure Regulator: Description and Operation Fuel Pressure Regulator PURPOSE The fuel pressure regulator controls fuel pressure supplied to the injectors. The regulator also traps fuel during engine shutdown, thus eliminating the possibility of vapor formation in the fuel line, and provides instant restarts and initial idle speed. OPERATION Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the injectors. Fuel in excess of that used by the engine is bypassed through the regulator and returns to the fuel tank. CONSTRUCTION The regulator is a spring loaded diaphragm operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to intake manifold vacuum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3268 Fuel Pressure Regulator: Service and Repair Fuel Pressure Regulator REMOVAL 1. Release pressure from fuel system at fuel pressure relief valve (Schrader) on fuel rail assembly. 2. Remove vacuum line at pressure regulator. Disconnecting Fuel Line 3. Disconnect the fuel return line from the fuel pressure regulator as follows: a. Disengage the locking tabs on the connector retainer and separate the retainer halves. b. Inspect the visible internal portion of the fitting for dirt accumulation. Clean the fitting before disassembly. c. To disengage the fitting from the regulator insert a fuel line coupling key into the slots in the coupling. d. Using the tool, pull the fitting from the regulator. 4. Remove two retaining screws from regulator housing. 5. Remove presure regulator assembly O-ring and washer. Discard washer and inspect O-ring for signs of cracks or deterioration. 6. Inspect fuel return tube for kinks and abrasions. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 3269 1. Install new washer and O-ring on regulator. 2. Lubricate fuel pressure regulator O-ring with a light oil. NOTE: Never use silicone grease. It will clog the injectors. 3. Ensure surfaces of fuel pressure regulator and fuel injection manifold are clean. 4. Install fuel pressure regulator on injector manifold. Tighten the retaining screws to 8-11 Nm (70-97 lb in). 5. Install vacuum line to regulator. 6. Install the fuel return line to the fuel presure regulator by pushing it onto the fuel pressure regulator line up to the shoulder on the regulator line. CAUTION: The connector should grip the regulator line securely. Fuel Pressure Regulator 7. Install the connector retainer and snap the two halves of the retainer together. 8. Install the cap on the relief valve if removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3273 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3274 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations Diagnostic Connector - Fuel Pump: Locations Diagnostic Connector - Fuel Pump Right rear corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Diagnostic Connector - Fuel Pump > Component Information > Locations > Page 3280 Diagnostic Lead Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications Fuel Pressure Relief Valve: Specifications Fuel Pressure Relief Valve .................................................................................................................. ..................................................... 8.0 Nm (71 in lb) Fuel Pressure Relief Valve Cap .............................................................................................................................................................. 1.0 Nm (9.0 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3284 Fuel Pressure Relief Valve: Description and Operation PURPOSE The fuel pressure relief valve is used to relieve fuel pressure from the fuel delivery system and diagnostic testing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Relief Valve <--> [Fuel Pressure Test Port] > Component Information > Specifications > Page 3285 Fuel Pressure Relief Valve: Service and Repair REMOVAL 1. If fuel injection supply manifold is mounted to engine, remove fuel tank tiller cap, then release pressure from System at fuel pressure relief valve on fuel injection supply manifold using Fuel Pressure Gauge T80L-9974-B. Fuel Injection Supply Manifold 2. Using a socket wrench, remove fuel pressure relief valve from fuel injection supply manifold. INSTALLATION Install fuel pressure relief valve and cap. Tighten fuel pressure relief valve to 3-6 Nm (27-53 lb in) and the cap to 1.0 Nm (9.0 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Box The Fuel Pump Relay is located in the power distribution box, on the right side of the engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3297 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3298 Fuel Pump Relay: Description and Operation OPERATION When the ignition switch is turned ON, the Electronic Engine Control (EEC) power relay is energized, providing power to the fuel pump relay for 1 to 2 seconds through the Powertrain Control Module (PCM) and an Inertia Fuel Shutoff (IFS) switch. Fuel pump power is provided through the fuel pump relay contacts, if the PCM does not receive an ignition signal within approximately one second after the ignition switch is turned to the "ON" position. A timer circuit in the PCM will open the ground circuit to the fuel pump relay, causing the fuel pump relay contacts to OPEN. This action stops the power supply to the fuel pump. When the ignition switch is turned to the "START" position, the PCM closes the ground circuit to the fuel pump relay, resuming operation of the fuel pump. After the ignition switch is returned to the "ON" position, power to the fuel pump is supplied through the fuel pump relay. The PCM monitors engine speed and opens the fuel pump relay ground circuit if the engine speed drops below 120 rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications Fuel Injection Supply Manifold Assembly: Specifications Head Stud Bolts ................................................................................................................................... .............................................. 10-14 Nm (7-10 ft lb) Fuel Supply Line .................................................................................................................................. ............................................ 20-24 Nm (15-18 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications > Page 3302 Fuel Injection Supply Manifold Assembly: Description and Operation Fuel Injection Supply Manifold PURPOSE The fuel supply manifold delivers high-pressure fuel from the vehicle fuel supply line to the fuel injectors. CONSTRUCTION The assembly consists of a preformed stamping with one injector connector for each fuel injector, a mounting flange for the fuel pressure regulator, a pressure relief valve for diagnostic testing or field service bleed down and mounted attachments that locate the fuel injection supply manifold and provides fuel injector nozzle tip retention. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications > Page 3303 Fuel Injection Supply Manifold Assembly: Service and Repair REMOVAL 1. Thoroughly clean the engine. 2. Release pressure from fuel system. 3. Remove the upper intake manifold assembly. 4. Disconnect the fuel supply line fitting at the fuel injection supply manifold. NOTE: If the fitting has been properly disengaged, the fitting should slide off the fuel pressure regulator with minimum effort. 5. Disconnect the fuel return line from the fuel pressure regulator as follows: Disconnecting Fuel Line a. Disengage the locking tabs on the connector retainer and separate the retainer halves. b. Inspect the visible internal portion of the fitting for dirt accumulation. Clean the fitting before disassembly. c. To disengage the fitting from the fuel pressure regulator, push the fitting toward the fuel pressure regulator, insert the fingers on Fuel Line Coupling Tool T9OP-955-A into the slots in the coupling. d. Using the tool, pull the fitting from the fuel pressure regulator. 6. Remove six Torx head stud bolts retaining the fuel injection supply manifold and remove the fuel injection supply manifold. 7. Remove the fuel injector nozzle tips from the fuel injection supply manifold and wipe cup clean with a clean, dry cloth. INSTALLATION 1. Make sure the fuel injector end caps are clean and free of contamination. Inspect fuel injector O-rings. Replace if required. CAUTION: Do not use silicone grease to lubricate 0-rings. Silicone grease can plug fuel injector nozzle tips. 2. Carefully wipe the fuel injector recesses in the intake manifold and make sure they are free of contamination. Grease the recesses with light grade oil 10W30 ESE-MLC153-E or equivalent. 3. Locate the three fuel injector nozzle tips on the right side recesses of the intake manifold. Then locate the three on the left. 4. Position the fuel injection supply manifold and press down firmly until the fuel injector nozzle tips are fully seated in the fuel injection supply manifold and lower intake manifold. The fuel injection supply manifold should be fully seated on the lower intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications > Page 3304 Fuel Injection Supply Manifold And Related Components 5. Install the six Torx head stud bolts and tighten to 10-14 Nm (7-10 ft lb). 6. Install the fuel supply line and tighten the fitting to 20-24 Nm (15-18 ft lb). 7. Make sure fuel line is clean. Install the fuel return line to the fuel pressure regulator by pushing it onto the fuel pressure regulator line up to the shoulder on the regulator line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications > Page 3305 CAUTION: The connector should grip the regulator line security. 8. Install the connector retainer and snap the two halves of the retainer together. 9. Install the upper intake manifold. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation DESCRIPTION Fuel is drawn from the fuel tank mounted fuel pump and is delivered under pressure through the supply fuel tube and fuel filter to the fuel injection supply manifold, and then to the fuel injectors. CONSTRUCTION Nylon fuel tubing is made from material which is proven to be acceptable for use with commercially available fuel. It is resistant to most environmental conditions. NOTE: Avoid using alternate tubing material as this could pose a hazard in service. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Nylon Fuel Lines Fuel Return Line: Service and Repair Nylon Fuel Lines Splicing Nylon to Nylon Splicing Service Combinations 1. Relieve fuel system pressure. If necessary, drain fuel tank. 2. Cut out damaged section of tubing and retain as a guide. 3. Cut a section of service tubing (type 11 or 12 nylon available in 1/4 and 5/16-inch sizes) to the same length as the damaged section of tubing. NOTE: To make hand-insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. CAUTION: Do not use any heating method except hot water to repair nylon tubing. Temperatures above 100°C (212°F) cause the nylon to soften and will not seal on the barbed connectors. Replacing nylon line in the engine compartment requires heat protective Hypalon hose. 4. Select the proper (1/4 or 5/16-inch) barbed connectors for completing the splice. Two connectors are required for each splice. 5. Install the barbed connectors into each end of the replacement tubing using boiling water. 6. Install clips onto any tubes which might be difficult to access once the final splices are completed. 7. Install four keystone clamps loosely onto the original nylon tubing before beginning Step 8. 8. Complete the splice of the replacement nylon to the original nylon tubing at both ends. Refer to the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Nylon Fuel Lines > Page 3311 9. Tighten the clamps in the locations shown in the illustration. 10. Install any remaining clips which were removed for service and check that the tubes are secured in the original clips. 11. Fill fuel tank, start engine and check for leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Service and Repair > Nylon Fuel Lines > Page 3312 Fuel Return Line: Service and Repair Steel Fuel Lines NOTE - The tubes attached to the vehicle underbody may be serviced and repaired. The metal underbody tubes must be cut and formed out of rolls of fuel system service tubing available at the dealerships. - A damaged section of tubing can be cut out of the existing line and replaced by a comparable service tubing section, spliced into the line by means of threaded fasteners and connectors. - All replacement hoses must be serviced as assemblies. Refer to push connect fitting installation for connecting procedure. Bulk fuel hose must not be used to service tubing in high-pressure fuel systems. REMOVAL 1. Drain the fuel from the fuel tank. 2. Disconnect the line(s) at the fuel tank and at the engine. Remove the lines from the holding clips along the underbody. Remove all damaged hoses and tube sections. INSTALLATION Ferrule NOTE: After disassembly of the flareless fitting joint, such as at the fuel hose to fuel line connection, the flareless fitting can be reassembled. To reassemble, reconnect the threaded fitting and seat the ferrule to be finger-tight. When the ferrule is seated, draw the nut up approximately one-sixth to one-third of a turn with a wrench to complete the tightening operation. 1. Cut a new section of tubing to approximately the same length as the section to be replaced, allowing for the threaded connectors/fasteners. 2. Bend the tube section to conform to the contour of the original tube. 3. Square the ends of the cut tubing with a file. Remove burrs. Blow out any particles with compressed air. 4. Position the lines in the underbody clips. Do not tighten at this time. 5. Assemble the fitting by sliding the nut over the tubing with threaded (open) end out. 6. Slide the ferrule on the tubing with the cutting edge out; the large head end should be inside of the nut. 7. Lubricate the ferrule and the threads on the fasteners with oil. 8. Bottom the tube in the fining and tighten the nut until the ferrule just grips the tube. When the tube can no longer be turned by hand, the ferrule has started to grip the tube. 9. After the ferrule grips the tube, tighten the nut one full turn. 10. Tighten the fuel line to the underbody clips to secure the fuel lines. 11. Fill the fuel tank and check for leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation DESCRIPTION Fuel is drawn from the fuel tank mounted fuel pump and is delivered under pressure through the supply fuel tube and fuel filter to the fuel injection supply manifold, and then to the fuel injectors. CONSTRUCTION Nylon fuel tubing is made from material which is proven to be acceptable for use with commercially available fuel. It is resistant to most environmental conditions. NOTE: Avoid using alternate tubing material as this could pose a hazard in service. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Nylon Fuel Lines Fuel Supply Line: Service and Repair Nylon Fuel Lines Splicing Nylon to Nylon Splicing Service Combinations 1. Relieve fuel system pressure. If necessary, drain fuel tank. 2. Cut out damaged section of tubing and retain as a guide. 3. Cut a section of service tubing (type 11 or 12 nylon available in 1/4 and 5/16-inch sizes) to the same length as the damaged section of tubing. NOTE: To make hand-insertion of the barbed connectors into the nylon easier, the tube end must be soaked in a cup of boiling water for one minute immediately before pushing the barbs into the nylon. CAUTION: Do not use any heating method except hot water to repair nylon tubing. Temperatures above 100°C (212°F) cause the nylon to soften and will not seal on the barbed connectors. Replacing nylon line in the engine compartment requires heat protective Hypalon hose. 4. Select the proper (1/4 or 5/16-inch) barbed connectors for completing the splice. Two connectors are required for each splice. 5. Install the barbed connectors into each end of the replacement tubing using boiling water. 6. Install clips onto any tubes which might be difficult to access once the final splices are completed. 7. Install four keystone clamps loosely onto the original nylon tubing before beginning Step 8. 8. Complete the splice of the replacement nylon to the original nylon tubing at both ends. Refer to the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Nylon Fuel Lines > Page 3318 9. Tighten the clamps in the locations shown in the illustration. 10. Install any remaining clips which were removed for service and check that the tubes are secured in the original clips. 11. Fill fuel tank, start engine and check for leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Nylon Fuel Lines > Page 3319 Fuel Supply Line: Service and Repair Steel Fuel Lines NOTE - The tubes attached to the vehicle underbody may be serviced and repaired. The metal underbody tubes must be cut and formed out of rolls of fuel system service tubing available at the dealerships. - A damaged section of tubing can be cut out of the existing line and replaced by a comparable service tubing section, spliced into the line by means of threaded fasteners and connectors. - All replacement hoses must be serviced as assemblies. Refer to push connect fitting installation for connecting procedure. Bulk fuel hose must not be used to service tubing in high-pressure fuel systems. REMOVAL 1. Drain the fuel from the fuel tank. 2. Disconnect the line(s) at the fuel tank and at the engine. Remove the lines from the holding clips along the underbody. Remove all damaged hoses and tube sections. INSTALLATION Ferrule NOTE: After disassembly of the flareless fitting joint, such as at the fuel hose to fuel line connection, the flareless fitting can be reassembled. To reassemble, reconnect the threaded fitting and seat the ferrule to be finger-tight. When the ferrule is seated, draw the nut up approximately one-sixth to one-third of a turn with a wrench to complete the tightening operation. 1. Cut a new section of tubing to approximately the same length as the section to be replaced, allowing for the threaded connectors/fasteners. 2. Bend the tube section to conform to the contour of the original tube. 3. Square the ends of the cut tubing with a file. Remove burrs. Blow out any particles with compressed air. 4. Position the lines in the underbody clips. Do not tighten at this time. 5. Assemble the fitting by sliding the nut over the tubing with threaded (open) end out. 6. Slide the ferrule on the tubing with the cutting edge out; the large head end should be inside of the nut. 7. Lubricate the ferrule and the threads on the fasteners with oil. 8. Bottom the tube in the fining and tighten the nut until the ferrule just grips the tube. When the tube can no longer be turned by hand, the ferrule has started to grip the tube. 9. After the ferrule grips the tube, tighten the nut one full turn. 10. Tighten the fuel line to the underbody clips to secure the fuel lines. 11. Fill the fuel tank and check for leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3320 Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3321 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Page 3322 8107 - 7-Piece Line Disconnect Set Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Pipe <--> [Fuel Filler Hose] > Component Information > Specifications Fuel Filler Pipe: Specifications Filler Pipe Screws ................................................................................................................................ .......................................... 3.0-4.0 Nm (27-35 lb in) Screw Clamp ....................................................................................................................................... .......................................... 3.0-4.0 Nm (27-35 lb in) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Pipe <--> [Fuel Filler Hose] > Component Information > Specifications > Page 3327 Fuel Filler Pipe: Service and Repair Fuel Tank And Filler Pipe REMOVAL 1. Loosen the screw clamp attaching fuel filler hose to tank. 2. Loosen screw clamp attaching fuel fill vent hose to tank. 3. Remove the three screws attaching the fuel filler pipe assembly. 4. Remove ground strap screw from frame. 5. Detach fuel filler and vent systems from fuel tank and remove through frame rail/body side void. INSTALLATION 1. Position the fuel filler/vent system and attach the hoses to the tank. 2. Position the filler neck to the body and install the three filler pipe screws. Tighten screws to 3.0-4.0 Nm (27-35 lb in). 3. Tighten the screw clamp attaching the fuel filler hose assembly to 3.0-4.0 Nm (27-35 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Pipe <--> [Fuel Filler Hose] > Component Information > Specifications > Page 3328 4. Tighten the screw clamp attaching the fuel vent hose assembly to 3.0-4.0 Nm (27-35 lb in). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation PURPOSE To supply an electrical signal to operate the fuel gauge. OPERATION The Sender is a variable resistor connected to a float in the fuel tank, which determines the amount of fuel in tank. When fuel is low, resistance is low (22.5 ohms); when fuel is high, resistance is high (145 ohms). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications Idle Air Control (IAC) Valve: Electrical Specifications IDLE AIR CONTROL (IAC) SOLENOID Solenoid resistance ............................................................................................................................. ................................................... 6.0-13.0 ohms Solenoid to case resistance ................................................................................................................................................... greater than 10,000 ohms IAC signal from PCM ........................................................................................................................................................ 3.0-11.5 volts at 3000 rpm Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications > Page 3336 Idle Air Control (IAC) Valve: Mechanical Specifications IDLE AIR CONTROL VALVE TORQUE SPECIFICATION Retaining screws ................................................................................................................................. ...................................... 9-11 Nm (80-97 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3337 Idle Air Control (IAC) Valve: Diagrams IAC Solenoid CIRCUIT / WIRE COLOR IAC / white/light blue VPWR / red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3338 Idle Air Control (IAC) Valve: Description and Operation PURPOSE The Idle Air Control (IAC) solenoid allows the Powertrain Control Module (PCM) to accurately control engine idle speed under a variety of conditions. The IAC solenoid is driven by an output signal from the PCM and allows intake airflow to bypass the throttle plates. In addition to normal idle speed control the IAC solenoid also functions as a deceleration dashpot and allows for idle speed changes during periods of increased engine load (A/C, electrical). The IAC solenoid also plays an integral role in Adaptive Strategy correction. The PCM monitors the engine condition and adjusts the IAC calibration to correct for wear and aging of components. NOTE: Whenever an IAC component is replaced or cleaned it is recommended that the Keep Alive Memory (KAM) be be cleared. The vehicle may exhibit idle concerns until new adaptive values are learned. CONSTRUCTION A duty cycle driven solenoid is directly linked to a reverse seated pintle valve. Hitachi Idle Air Control (IAC) Valve And Solenoid Hitachi With Vent/Filter This type of IAC solenoid is not serviceable and cannot be cleaned. Idle Air Control Solenoid OPERATION The IAC solenoid receives a 12 volt signal from circuit VPWR. The ground supply to the IAC solenoid is controlled by the PCM. The PCM controls the amount of IAC operation by varying the duty cycle of the ground signal. The IAC solenoid is linked directly to a pintle valve which controls the amount of intake airflow allowed to bypass the throttle plates. RELATED DIAGNOSTIC TROUBLE CODES DTC 412 Indicates that during the Key On Engine Running (KOER) self-test, engine rpm could not be controlled within the self-test limit band. DTC 415 Indicates the IAC adaptive learning has reached the minimum learning limit (the valve is reducing air flow as much as possible). DTC 416 Indicates the IAC adaptive learning has reached the maximum learning limit (the valve is admitting as much air flow as possible). NOTE: Idle speed surging commonly results when the IAC solenoid reaches the limits of its operation. The IAC solenoid cannot compensate for the required change in idle speed which results in the engine surging between the upper and lower limits of the IAC system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures Idle Air Control (IAC) Valve: Procedures CAUTION: The Idle Air Control (IAC) valve CANNOT be cleaned unless removed from the engine. CAUTION: Do not clean black plastic IAC valves. Use only specified cleaner. Do not spray directly on throttle plate or use any type of scrubbing method. Do not run engines of vehicles with mass airflow sensors during cleaning. Cleanable/Non-Cleanable Idle Air Control Valves RECOMMENDED CLEANING PROCEDURE 1. Ensure IAC valve is operating properly. 2. Remove air cleaner outlet tube. 3. Disconnect fuel charging wiring connector from IAC valve. 4. Connect Rotunda Air Bypass Actuator 113-00009 and Injector Tester/Cleaner 113-00001 or equivalent. 5. Start the actuator. Do not start engines of vehicles equipped with mass airflow sensors. 6. Spray Carburetor Tune-Up Cleaner D9AZ-19579-BA (ESR-M14P9-A) or equivalent into IAC valve passage for five seconds while actuator is operating. 7. Turn the actuator off. Allow solvent to soak for 15 minutes. 8. Turn actuator on. 9. Spray carburetor cleaner into IAC valve passage for no more than six seconds. 10. Turn actuator off. 11. Install air cleaner outlet tube. Start actuator and engine and run engine for one minute to dry out solvent residue. 12. Disconnect actuator from IAC valve. Connect fuel charging wiring connector to IAC valve. 13. Start engine and check for normal operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control (IAC) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 3341 Idle Air Control (IAC) Valve: Removal and Replacement Idle Air Control Valve REMOVAL 1. Disconnect the Idle Air Control (IAC) valve connector from the fuel charging wiring. 2. Remove the two IAC valve retaining bolts. 3. Remove the IAC valve and IAC gasket. NOTE: If scraping is necessary, be careful not to damage IAC valve, throttle body gasket surfaces or drop material into throttle body. INSTALLATION 1. Make sure that both throttle body and valve gasket surfaces are clean. 2. Install IAC gasket on throttle body surface and mount IAC valve, securing it with two retaining screws. Tighten to 9-11 Nm (80-97 in lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations INERTIA FUEL SHUTOFF SWITCH LOCATION Inertia Fuel Shutoff Switch Location Located on the toe-board to the right of the transmission hump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 3345 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "OFF" in the event of a collision. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump looses power. The inertia switch must then be manually reset before the engine can be restarted. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 3346 Fuel Pump Inertia Switch: Service and Repair WARNING: Do not reset the inertia switch button if you see or smell fuel. 1. Turn ignition switch to OFF. 2. Check for leaking fuel in the engine compartment, fuel lines and fuel tank. 3. If no fuel is apparent, reset the Inertia Fuel Shutoff (IFS) switch by pushing the reset button on top of switch. 4. Turn ignition switch to START for a few seconds, then to OFF. 5. Again, check for leaking fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3350 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3351 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Power Distribution Box The Fuel Pump Relay is located in the power distribution box, on the right side of the engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3358 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3359 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3360 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3361 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3362 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3363 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3364 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3365 Fuel Pump Relay: Description and Operation OPERATION When the ignition switch is turned ON, the Electronic Engine Control (EEC) power relay is energized, providing power to the fuel pump relay for 1 to 2 seconds through the Powertrain Control Module (PCM) and an Inertia Fuel Shutoff (IFS) switch. Fuel pump power is provided through the fuel pump relay contacts, if the PCM does not receive an ignition signal within approximately one second after the ignition switch is turned to the "ON" position. A timer circuit in the PCM will open the ground circuit to the fuel pump relay, causing the fuel pump relay contacts to OPEN. This action stops the power supply to the fuel pump. When the ignition switch is turned to the "START" position, the PCM closes the ground circuit to the fuel pump relay, resuming operation of the fuel pump. After the ignition switch is returned to the "ON" position, power to the fuel pump is supplied through the fuel pump relay. The PCM monitors engine speed and opens the fuel pump relay ground circuit if the engine speed drops below 120 rpm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations PCM Power Relay: Locations Component Locations UNDERHOOD VIEW Mounted in power distribution box on right fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3369 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > PCM Power Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 3370 PCM Power Relay: Description and Operation PURPOSE The Powertrain Control Module (PCM) power relay provides power to the PCM. The PCM power relay also provides reverse battery protection for the PCM and related actuator assemblies. CONSTRUCTION The relay is a single pole double throw type. This relay does not have an internal diode and is used with a separate stand alone diode. OPERATION The PCM power relay is energized in "RUN" or "START" through the ignition switch. When energized, battery voltage (B+) flows through the relay. This voltage powers the PCM and its outputs. When the ignition switch is turned "OFF", the relay de-energizes, stopping B+ to the PCM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation Rollover Valve: Description and Operation Fuel Vapor Valve PURPOSE Permits fuel vapors to be vented to the charcoal canister, while restricting liquid fuel. In the event of vehicle roll-over, the float closes off the valve, preventing fuel from escaping and saturating the charcoal canister. OPERATION Fuel vapors generated, enter the valve from the bottom, rise upward past the float, and out through a single vapor line to the carbon canister. If liquid fuel enters the valve assembly, the float will rise upward and close the orifice. As fuel is drained back into the fuel tank, the spring attached to underside of valve pulls the float downward, exposing the orifice. If the fuel vapor line to the canister becomes kinked or plugged, causing extreme pressures to build inside fuel tank, the vapor valves purge port opens to provide pressure relief. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Description and Operation > Page 3374 Rollover Valve: Service and Repair REMOVAL and INSTALLATION 1. Depressurize the fuel system. 2. Remove fuel tank. 3. Remove fuel vapor valve from top of fuel tank. 4. To install, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3384 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3385 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3391 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3392 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3397 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement Mass Air Flow (MAF) Sensor: All Technical Service Bulletins Mass Air Flow Sensor - Assembly Replacement Article No. 96-22-5 10/21/96 MASS AIR FLOW SENSOR - REPLACEMENT AS AN ASSEMBLY - SERVICE TIP FORD: 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR, EXPLORER, RANGER 1993-97 VILLAGER 1994-96 BRONCO 1994-97 ECONOLINE 1995-97 F-150, WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: The Mass Air Flow (MAF) sensor is not designed to be removed from its body (die-cast or plastic) for servicing. The sensing elements located inside the by-pass tube can be damaged by poking/probing/touching. ACTION: Service the MAF sensor as an assembly (refer to Figure 1). WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Mass Air Flow (MAF) Sensor: > 96225 > Oct > 96 > Mass Air Flow Sensor - Assembly Replacement > Page 3403 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 204000, 206000, 607000, 610000, 610500, 611000, 611500, 614000, 614500, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications Mass Air Flow Meter Signal Voltage Sensor Data Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Electrical Specifications > Page 3406 Mass Air Flow (MAF) Sensor: Mechanical Specifications MASS AIRFLOW TORQUE SPECIFICATIONS Sensor retaining nuts ........................................................................................................................... ................................................. 10 Nm (7 ft lb) Air cleaner tube retaining clamp ................................................................................................................................................. 2-3 Nm (18-27 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3407 Mass Air Flow (MAF) Sensor: Locations Component Locations The Mass Air Flow (MAF) Sensor is mounted on the air cleaner housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3408 Mass Air Flow (MAF) Sensor: Diagrams Black Connector Testing Schematic BLACK CONNECTOR Gray Connector Testing Schematic GRAY CONNECTOR Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3409 Mass Air Flow (MAF) Sensor: Description and Operation Mass Air Flow Sensor PURPOSE The Mass Air Flow (MAF) sensor measures the total volume and mass of air flowing into the engine. This value is one of the major factors used by the Powertrain Control Module (PCM) in determining the fuel injection base pulse width and ignition timing advance. CONSTRUCTION The MAF sensor is located directly in the air flow path between the air cleaner housing and the throttle body. The sensor is designed and located such that all air entering the intake manifold must flow through it. Located in the MAF sensor directly in the airstream are two platinum wires, a hot wire heated by electrical current and a cold reference wire. The MAF sensor uses the air flow across these wires to calculate its output. OPERATION The MAF sensor operates on the principle that if the hot wire is maintained at a constant temperature above ambient, the thermal loss exhibited by the hot wire is proportional to the total mass of air flowing across it. The sensor maintains the hot wire exactly 200°C (392°F) hotter than the reference (cold) wire. The MAF sensor then measures the amount of electrical current required to maintain this temperature difference and converts this value to an analog DC voltage. This output varies directly with the mass air flow rate and ranges from 0.5 to 4.5 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 129 - Insufficient MAF sensor output change during the dynamic response (snap throttle) test. DTC 157 - MAF sensor output went below the minimum value of 0.4 volts (continuous memory code). DTC 158 - MAF sensor output went above the maximum value of 4.5 volts (continuous memory code). DTC 159 - MAF sensor output was measured out of range during a self-test, >0.7 volts during the Key On Engine Off (KOEO) test and not between 0.2-1.5 volts during the Key On Engine Running (KOER) test. DTC 184 - MAF sensor output is higher than expected. DTC 185 - MAF sensor output is lower than expected. Note: DTC 184, 185 were intended to detect in-range failures of the MAF sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, throttle position sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications > Page 3410 Mass Air Flow (MAF) Sensor: Service and Repair Mass Air Flow Sensor REMOVAL 1. Loosen air cleaner outlet tube clamp at Mass Air Flow Sensor (MAF) and remove tube from sensor. 2. Disconnect electrical connector to MAF sensor. 3. Remove four retaining nuts. 4. Remove MAF sensor and discard old gasket. INSTALLATION 1. Clean sealing surfaces of engine air cleaner and MAF sensor of old gasket material. 2. Position MAF sensor and new gasket to air cleaner cover aligning bolt holes. 3. Install four retaining nuts. Tighten to 10 Nm (7 ft lb). 4. Install air cleaner outlet tube (9B659) to MAF sensor. Tighten retaining clamp to 2-3 Nm (18-27 in lb). 5. Connect electrical connector to MAF sensor. 6. Start engine and check for air leaks and correct sensor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations INERTIA FUEL SHUTOFF SWITCH LOCATION Inertia Fuel Shutoff Switch Location Located on the toe-board to the right of the transmission hump. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 3414 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "OFF" in the event of a collision. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump looses power. The inertia switch must then be manually reset before the engine can be restarted. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations > Page 3415 Fuel Pump Inertia Switch: Service and Repair WARNING: Do not reset the inertia switch button if you see or smell fuel. 1. Turn ignition switch to OFF. 2. Check for leaking fuel in the engine compartment, fuel lines and fuel tank. 3. If no fuel is apparent, reset the Inertia Fuel Shutoff (IFS) switch by pushing the reset button on top of switch. 4. Turn ignition switch to START for a few seconds, then to OFF. 5. Again, check for leaking fuel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3420 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3421 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3422 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3423 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3424 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3425 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3426 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3429 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3430 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3431 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3432 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3433 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle Body Assembly Screws .................................................................................................................................................... 8-12 Nm (70-106 lb in) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 3437 Throttle Body: Description and Operation Throttle Body Assembly PURPOSE The throttle body provides control of engine airflow in all driving modes, except at idle speeds. The idle air control valve provides supplemental airflow to maintain the proper engine idle speed. CONSTRUCTION The single-piece aluminum die cast body has a single bore with an air bypass channel around the throttle plate. This bypass channel controls both cold and warm engine idle airflow control as regulated by an idle air control valve mounted directly to the body. Other features of the throttle body include: - Throttle angle is controlled by multiple-link, progressive opening throttle linkage. - A pre-set stop to locate the Wide Open Throttle (WOT) position. - A throttle body mounted throttle position sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > Check Throttle Body Condition Throttle Body: Testing and Inspection Check Throttle Body Condition ^ Remove the air intake hose and check for oil sludging or oil vapors in the throttle body. ^ Reconnect the air intake hose. ^ Check throttle body and components for cracks, looseness, or other damage. ^ Without removing throttle body from engine, check the integrity of vacuum and electrical lines for looseness, pinching, mis-routing, corrosion, or other obvious damage. ^ Check the throttle lever for freedom of movement. ^ Are the throttle body and attachments OK? YES -- Go to Check Throttle Valves. See: Check Throttle Valves NO -- Service or replace the throttle body and/or related components as required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > Check Throttle Body Condition > Page 3440 Throttle Body: Testing and Inspection Check Throttle Valves ^ Remove the throttle body from the engine. ^ Check that the throttle valve(s) moves smoothly from the fully closed to the fully open position. ^ Check for loose, bent, or damaged valve(s), and for contamination that can cause binding. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > Page 3441 Throttle Body: Service and Repair Throttle Body Assembly REMOVAL 1. Remove the snow/ice shield and disconnect throttle cable from ball stud. 2. Disconnect the throttle position sensor electrical connector. 3. Remove the air inlet duct at throttle body. 4. Disconnect the canister purge hose from the fitting beneath the throttle body. 5. Remove the four screws retaining the throttle body to the upper intake manifold. 6. Carefully separate the air throttle body from the upper intake manifold. 7. Remove and discard gasket between throttle body and upper intake manifold. INSTALLATION 1. Make sure that both the throttle body and upper intake manifold gasket surfaces are clean. NOTE: If scraping is necessary, be careful not to damage the gasket surfaces or allow material to enter the manifold. 2. Install the throttle body gasket on two screws installed in the throttle body. 3. Install throttle body to upper intake manifold. 4. Secure throttle body assembly to upper intake manifold with the two remaining screws. Tighten all screws to 8-12 Nm (70-106 lb in). 5. Connect the throttle position sensor electrical connector. 6. Connect canister purge hose to fitting beneath throttle body. 7. Install the snow/ice shield. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Accelerator Cable - Service Procedures/Tips Accelerator Cable/Linkage: Technical Service Bulletins Accelerator Cable - Service Procedures/Tips Article No. 94-15-16 07/27/94 ^ ACCELERATOR CABLE - NEW SERVICE PROCEDURES - SERVICE TIPS ^ ACCELERATOR CABLE - SERVICE TIPS - REVISED DIAGNOSTIC PROCEDURES LIGHT TRUCK: 1989-94 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991-94 EXPLORER ISSUE: Some Accelerator Cables are being replaced without an accurate check for cable wear or damage. Some cables may be replaced unnecessarily. ACEELERATOR PEDAL AND THROTTLE BODY DIAGNOSIS TEST A Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Accelerator Cable - Service Procedures/Tips > Page 3446 TEST B TEST C (EXCEPT WINDSTAR) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Accelerator Cable - Service Procedures/Tips > Page 3447 TEST C (WINDSTAR) ACTION: Refer to the Diagnostic Charts for the proper service procedure if an Accelerator Cable concern is suspected. Follow the instructions carefully, and do not replace the accelerator cable before it is examined and determined to be worn or damaged. NOTE: ACCELERATOR CABLE SHOULD NOT BE LUBRICATED AND IS NOT SERVICEABLE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Page 3448 Accelerator Cable/Linkage: Specifications Accelerator Cable Bracket Bolt ...................................................................................................................................................... 22-28 Nm (17-20 lb ft) Accelerator Shield Screw .................................................................................................................... ............................................... 7-9 Nm (62-79 lb in) Kickdown Cable Bracket Bolt (A/T Vehicles Only) ...................................................................................................................... 17-23 Nm (13-17 lb ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Page 3449 Accelerator Cable/Linkage: Diagrams Accelerator Cable Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Technical Service Bulletins > Page 3450 Accelerator Cable Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Accelerator Cable/Linkage: Symptom Related Diagnostic Procedures Accelerator Pedal Is Hard to Push Down CONDITION - Accelerator pedal is hard to push down or has a rough, raspy or sticky feel. POSSIBLE SOURCE - Full pedal travel is restricted. - Worn or damaged cable. - Restricted pedal operation. ACTION - Go to Test A. See: Pinpoint Tests/Test A High Engine Idle Speed CONDITION - High engine idle speed. POSSIBLE SOURCE - Cable ball socket extends beyond the throttle lever ball stud when cable is disconnected from throttle lever. - Restricted foot pedal operation. - Worn or damaged cable. - Refer to the throttle body diagnosis procedure. - Adjust carpet, floor mat or wiring as required. ACTION - Go to Test C. See: Pinpoint Tests/Test C Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3453 Accelerator Cable/Linkage: Pinpoint Tests Test A ^ Disconnect the cable end from the throttle body linkage. ^ Ensure the disconnected end of cable does not come in contact the with any of the surrounding parts. ^ Operate the pedal by hand. ^ Is the full pedal travel to WOT restricted by carpeting, floor mats, etc.? YES -- Remove restriction to pedal travel. NO -- Go to Test B. See: Test B Test B ^ Cable end should remain disconnected. ^ Operate the pedal by foot. ^ Is the pedal operation smooth? NOTE: The accelerator cable should not be lubricated and is not a serviceable item. YES -- Refer to the throttle body diagnosis procedures. NO -- Check the foot pedal assembly for free operation or check for worn or damaged cable by following Test C. See: Test C Test C ^ Disconnect the cable from the ball stud at the throttle body. ^ Ensure the disconnected end of the cable does not come in contact with any of the surrounding parts. ^ From inside the vehicle, pull the cable core wire through its full travel. - Does it feel rough, sticky or restricted? ^ Release the core wire. - Does it stick or hesitate before returning to its original position? ^ Compress the spring at the throttle body end of the cable and observe the cable as it returns to its original position. ^ Does the spring stick or fail to return to its original position at a rapid rate? YES -- If Yes to any of the questions: Replace the cable. NO -- If No to all of the questions: Cable is functioning properly. Refer to the Throttle Body / Testing and Inspection / Procedures or adjust the carpet, floor mat, etc., as required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Accelerator Cable Accelerator Cable/Linkage: Service and Repair Accelerator Cable WARNING: No surrounding engine compartment components such as wiring or hoses may contact any moving member of the accelerator controls. All vehicles are to be checked for return to idle as follows: No perceptible hesitation or prevention of return to idle may occur during slow removal of the foot from the accelerator pedal and shaft starting at the fully depressed wide open throttle position. REMOVAL 1. Remove the accelerator control splash shield. 2. Disconnect accelerator cable from throttle lever ball stud at throttle body. Grasp cable at ball stud end and carefully remove accelerator cable from the ball stud. Take special care when removing accelerator cable so that the accelerator cable end tube and guide tube are not damaged. 3. Remove accelerator cable from accelerator cable bracket on intake manifold. 4. From inside vehicle, remove accelerator cable end from top of accelerator pedal assembly. 5. Collapse retaining clips at dash panel and push accelerator cable through dash panel into engine compartment. Remove accelerator cable assembly. INSTALLATION 1. Install accelerator cable through dash panel into passenger compartment, making sure retaining clips are fully seated. 2. From inside vehicle, attach accelerator cable end to accelerator pedal assembly, seating returner on accelerator cable end onto accelerator pedal assembly. 3. Install accelerator cable in attaching accelerator cable bracket on intake manifold, making sure that tab or pin on accelerator cable aligns with hole in accelerator cable bracket. 4. Attach accelerator cable end to throttle lever ball stud at throttle body. Carefully push only on the end of accelerator cable when snapping accelerator cable end over ball stud. 5. Install accelerator control splash shield. 6. Adjust transmission kickdown cable, if so equipped. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Cable/Linkage <--> [Throttle Cable/Linkage] > Component Information > Service and Repair > Accelerator Cable > Page 3456 Accelerator Cable/Linkage: Service and Repair Accelerator Cable Bracket REMOVAL and INSTALLATION 1. Remove the accelerator control splash shield, if equipped. 2. Remove the accelerator cable from the accelerator cable bracket. 3. Remove the kickdown cable from the accelerator cable bracket, if equipped. 4. Remove the accelerator cable bracket holding screws and remove the accelerator cable bracket from the upper intake manifold. 5. To install, reverse removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips Technical Service Bulletin # 94264 Date: 941226 Throttle Position Sensor - Function and Diagnostic Tips Article No. 94-26-4 12/26/94 THROTTLE POSITION SENSOR (TPS) - FUNCTION AND DIAGNOSTIC TIPS RECAP - TPS APPLICATION CHART OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 603300, 610000, 611000, 619400, 698200 General Information FORD: 1993-94 TEMPO 1993-95 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS SHO, TAURUS, THUNDERBIRD 1995 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-95 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995 MYSTIQUE LIGHT TRUCK: 1993-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1993-95 F SERIES ISSUE: The following Throttle Position Sensor (TPS) TSB has been developed for service use. This TSB includes the following topics: ^ Description And Background Of TPS ^ (A1) and (A2) - Diagnostic Trouble Codes (Service Tips) ^ (B) Troubleshooting The TPS ^ (C) TPS Application Charts ACTION: If TPS diagnosis or repair is required, refer to the following procedures for service details. Description The Throttle Position Sensor (TPS) is a rotary potentiometer that provides a voltage signal to the Powertrain Control Module (PCM) that is linearly proportional to the throttle plate/shaft angular position. The TP sensor has a three-blade electrical connector that is plated. The plating increases the corrosion resistance on terminals and increases the connector durability. The TP sensor is mounted on the throttle body and is non-adjustable. As the TP sensor is rotated by the throttle shaft, four (4) operating conditions are determined by the PCM from the TP sensor. The four (4) vehicle operating conditions are: ^ Closed throttle (idle or deceleration) ^ Part throttle (cruise, moderate acceleration) ^ Wide open throttle (maximum acceleration, de-choke on crank and A/C shut-off) ^ Throttle angle rate. Background Recently, revisions have been made to the TPS, which have improved reliability and durability. (A1) - Diagnostic Trouble Codes (DTC) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3461 A key difference between EEC-IV, OBD I and EEC-V, OBD II is the monitors. EEC-IV monitors are designed to identify system and component issues. EEC-V monitors are designed to measure the ability of systems and components to maintain low emission levels. To minimize the replacement of good components, be advised that the following non-EEC areas may be the issue: ^ Excessive blow-by ^ PCV malfunction ^ Vacuum leaks ^ Fuel pressure ^ Throttle sticking or linkage binding. (A2) - EEC-IV Diagnostic Trouble Codes (DTC) When a Diagnostic Trouble Code (DTC) 121, 124 or 125 are set in continuous memory, the technician is directed to Pinpoint Test G of the Powertrain Control/Emissions Diagnosis (PC/ED) Manual. Pinpoint Test G is named: In-Range MAF/TP/Fuel lnjector Pulse Width Test. The description of the test is as follows: ^ EEC-IV DTC Code 121, 124, and 125 Description. This In-Range Self-Test was designed to identify in-range concerns of the MAF sensor, TP sensor, or the fuel delivery system. The PCM will use information from these three (3) areas based on vehicle load to generate three (3) independent values. The three (3) independent values will be continuously monitored by the PCM. If one (1) of the values differs significantly from the others during normal vehicle operation, a Continuous Memory Diagnostic Trouble Code (DTC) will be stored. EEC codes for the TPS are intended as a supplemental aid to diagnostics. They do not indicate the root cause since more than one (1) component can set the same code. For example: EEC-IV, OBD I Codes 122 and 123 and EEC-V, OBD II Codes P0122 and P0123 for "TP circuit too low" or "TP circuit too high", limit the condition to the TP circuit, connector, or vehicle harness. EEC-IV, OBD I Codes: 121, "TP inconsistent with air meter", 124, "TP higher than expected", 125, "TP lower than expected" and OBD II Code P1121, "TP inconsistent with MAF sensor" are a result of a comparison of the TP signal to a given airflow. Any un-metered air (downstream of MAF) that enters the engine, either due to a mechanical situation or electrical sensor condition, may result in these codes. PC/ED Pinpoint Tests will guide you to the root cause and avoid customer repeat repairs. EEC-IV (OBD I) Codes 124 and 125 are set in memory as follows: Codes 124-125 are a comparison of a given airflow to the TPS voltage (throttle plate position). Code 124: The PCM has indicated that the airflow rate is too low for the position of the throttle plate angle. Causes for EEC-IV, OBD I Code 124: Air bypass solenoid flow low/blocked (MAF may indicate low during the event). ^ Throttle body obstructed. ^ EGR flow low. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor low. Code 125: The PCM has indicated that the airflow rate is too high for the position of the throttle plate. Causes of EEC-IV, OBD I Code 125: Air bypass solenoid high/stuck open (MAF may indicate high during this event). ^ EGR flow high. ^ TPS circuit concern when accompanied by Codes 122 or 123. ^ BP sensor high. These codes are designed to set while in the part throttle drive mode, and often the MIL light flashes on and off until the condition is gone. In some cases, it is difficult to repeat the codes in a test drive since the PCM requires a long drive time to calculate the error in the system. At other times, it may be difficult to repeat because the condition that set the code may be intermittent. Pinpoint Test G of the PC/ED Manual will guide you to the root cause. Causes of EEC Codes 122: TPS sensor circuit voltage above maximum. Causes of EEC codes 123: TPS sensor circuit voltage below minimum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3462 ^ Harness damage. ^ Connector damage or water in connector. ^ Defective TPS, open or short. ^ Check VREF for correct output. ^ Throttle plate not closing. (B) - Troubleshooting the TPS The following is a list of vehicle symptoms which have been associated with the TPS, but can also be related to other vehicle components. ^ Check engine light ^ Stalls/quits ^ Hesitation/stumble ^ Fast idle If an EEC error code has identified the TPS as suspect, perform PC/ED Manual pinpoint tests on the TPS. Testing the TPS in the vehicle electrical circuit: The TPS is supplied with a 5.0 volt reference signal. As the TPS senses throttle plate rotation, the output voltage changes to a value in the range of 0.4 volts to 4.8 volts depending on vehicle application. A voltmeter, New Generation Star Tester (NGS) or Service Bay Diagnostics System (SBDS) is the recommended test equipment for checking the TPS output. The reason SBDS or NGS are the preferred tools is that they allow TPS voltage monitoring without disturbing the connector. Many conditions can be caused by loose, dirty, oxidized, or poor connections that may correct themselves for a short time if the connector is disturbed during testing. This can mislead technicians into replacing a TPS that is okay, and the true cause, a bad connection, may return at some future time. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3463 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3464 Measuring the TPS voltage at idle is key when diagnosing a TPS since most of its operational life is within 10 degrees of idle. Figures 2 and 3 include a guide to TPS output voltages for 1993-95 model year vehicles. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3465 Figure 1 is a graph that shows how the TPS output voltage changes between engine idle and WOT conditions. The TPS voltage increases when the throttle is depressed. Idle is typically in the 0.4 volt to 1.2 volt range. (Refer to idle voltage range chart.) As the TPS senses plate rotation toward Wide Open Throttle (WOT), the voltage increases. WOT is typically in the 4.0 volt range. A voltmeter, NGS, or SBDS is the recommended test equipment for checking the TPS output. CAUTION: MANY VOLTMETERS WILL AUTOMATICALLY CHANGE RANGES WHEN MEASURING TPS OUTPUT FROM IDLE TO WOT. WHEN A VOLTMETER IS USED TO MEASURE TPS OUTPUT FROM IDLE TO WOT, THE METER SCALES OR CHANGES RANGES AUTOMATICALLY. THERE MAY BE AN ERRONEOUS METER DISPLAY UNTIL THE VOLTMETER HAS LOCKED TO THE APPROPRIATE VOLTAGE READING. THE ERRONEOUS METER DISPLAY DOES NOT REPRESENT A DEFECTIVE TPS. NOTE: IT IS RECOMMENDED THAT THE "RANGE LOCK' FEATURE ON MANY METERS BE SET FOR CHECKING TPS VOLTAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3466 Use the 0.00 range to measure TPS voltage. If your voltmeter does not change ranges automatically and the meter is set to millivolt scale when reading full range voltages, the meter display may not indicate a valid value. This can be misinterpreted as an open circuit or suspect TPS. Ensure the meter is set to volts for measuring full range voltage levels. (C) - Application Charts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Throttle Position Sensor - Function and Diagnostic Tips > Page 3467 Figures 2 and 3 are 1993-95 Throttle Position Sensor Service Part Application Charts for car and light truck. The charts also contain TPS idle voltage ranges. These idle voltage values should be used instead of the values published in the 1993-95 PC/ED Manuals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Angle Measurement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3470 Throttle Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Throttle position sensor ....................................................................................................................... ......................................... 1-2 Nm (9-18 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3471 Throttle Position Sensor: Locations All Except Limited Edition And Electronic Group The Throttle Position (TP) Sensor is attached to the throttle body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3472 Throttle Position Sensor: Diagrams TPS Diagram CIRCUIT / WIRE COLOR TP / gray/white VREF / brown/white SIG RTN / gray/red Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3473 Throttle Position Sensor: Description and Operation PURPOSE The Throttle Position (TP) sensor is a rotary potentiometer that determines throttle plate angle. The Powertrain Control Module (PCM) determines operating modes from the TP signal. These are: Closed throttle, idle or deceleration - Part throttle, cruise or moderate acceleration - Wide open throttle, maximum acceleration, dechoke on crank and A/C cutout - Throttle angle rate, acceleration pump type function - Transmission shift schedule CONSTRUCTION The TP sensor is mounted on the throttle body and is directly linked to the throttle shaft. The TP sensor is composed of a wiper arm that moves along a curved resistor. OPERATION The TP sensor measures travel of the throttle shaft to produce a continuously variable output signal proportional to the throttle plate position. Throttle Position Sensor Schematic The potentiometer functions as a voltage divider. A 5.0 volt reference signal is applied to one end (VREF) of a curved resistance material, with the other end grounded along the SIG RTN circuit. The TP sensor output signal is taken off a wiper arm (mechanically linked to the throttle shaft) that travels along the entire length of the curved resistor At closed throttle the TP wiper arm is nearer the ground side of the resistor resulting in a lower output, 0.6 volts at 0% throttle angle. At wide open throttle the TP wiper arm is nearer the reference voltage side of the resistor resulting in a higher output, 4.5 volts at 85% throttle angle. RELATED DIAGNOSTIC TROUBLE CODES DTC 23/121 - TP sensor output is out of the self-test range. DTC 63/122 - TP sensor output is below the minimum self-test value. DTC 53/123 - TP sensor output is above the maximum self-test value. DTC 124 - TP sensor output is higher than expected. DTC 125 - TP sensor output is lower than expected. Note: DTC 124, 125 were intended to detect in-range failures of the TP sensor. The PCM compares information from the Mass Air Flow (MAF) sensor, TP sensor, and fuel injection pulse width. If any one value appears to be out of line with the other two an in-range trouble code will be set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3474 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect Throttle Position (TP) sensor from fuel charging wiring. 2. Remove two TP sensor retaining screws. 3. Remove TP sensor and discard TP sensor gasket. INSTALLATION 1. Position TP sensor and gasket with connector facing rearward. 2. Secure TP sensor to throttle body with two retaining screws. Tighten to 1-2 Nm (9-18 in lb). 3. Connect electrical connector to TP sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Page 3479 Spark Plug Wire Assembly Vin X V6 Firing Order: 1 4 2 5 3 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Locations Ignition Timing Connector: Locations Connector Location The SPOUT connector shorting bar (C107), is located at the RF corner of the engine compartment, near EDIS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation Ignition Timing Connector: Description and Operation SPOUT / SAW Connector Operation Spout/SAW Connector DESCRIPTION The Spark Angle Word (SAW),or Spark Output (SPOUT) connector is used to open and close the circuit between the Powertrain Control Module (PCM)and the Ignition Control Module (ICM) for checking base timing. OPERATION When the SPOUT or SAW connector is inserted in the harness connector, the ICM operates according to PCM timing data (computed timing). When the SPOUT or SAW connector is removed from the harness connector, the ICM operates on the Profile Ignition Pickup (PIP) signal only (base timing). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation > Page 3486 Ignition Timing Connector: Description and Operation Octane Adjustment Switch Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Marks Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Calibration Resistor / Connector, Ignition > Component Information > Description and Operation Calibration Resistor / Connector: Description and Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 3498 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 3499 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3500 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3501 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3502 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3503 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Specifications Condenser: Specifications TIGHTENING SPECIFICATIONS Noise filter condenser .......................................................................................................................... ..................................... 40-61 In-lb (5-7 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3511 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3512 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3515 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3516 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3517 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3518 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3519 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3520 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3521 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3522 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3523 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3524 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3525 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The Profile Ignition Pickup (PIP) sensor is a Hall-effect type switch located in the distributor. It sends the Powertrain Control Module (PCM) information on engine speed and crankshaft position. The Hall device operates by the manipulation of magnetic fields. When a rotor vane ENTERS the space between the two halves of the stator pick-up, the magnetic field is altered, turning ON the signal to the PCM. When the vane LEAVES the stator gap, the magnetic field returns to normal, and the signal to the PCM is turned OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 3532 Spark Plug Wire Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 3533 Ignition Cable: Description and Operation PURPOSE Conducts high voltage from the ignition coil and deliver to each spark plug in proper sequence. CONSTRUCTION Secondary ignition wires are constructed with a carbon impregnated, multi-filament synthetic fiber core. To endure under hood temperatures, the core is surrounded by heat resistant rubber insulation. Built-in internal resistance suppresses radio static and eliminates interference. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Locations > Page 3534 Ignition Cable: Service and Repair Spark Plug Wire Assembly REMOVAL: 1. When removing spark plug wires from the spark plugs, use the spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug insulator to free the boot. 2. Use the special tool or equivalent to pull the boot from the plug. Do not pull on the wire directly, as it may become separated from the connector inside the boot. 3. To remove the wires from the coil pack, squeeze the locking tabs of the coil wire retainer and remove using a twisting and pulling motion. Do not pull on the wire. INSTALLATION: CAUTION: Proper installation of spark plug wires is critical to vehicle operation. If one spark plug wire is not properly installed on the spark plug or ignition coil, both spark plugs connected to that coil may not fire under load. 1. Whenever a high tension wire is removed for any reason from a spark plug or ignition coil, or a new high tension wire is installed, Silicone Dielectric Compound D7AZ-19A331-A or equivalent must be applied to the boot prior to installation. Using a small tool, coat the entire interior surface of the boot. 2. Install each wire on the proper ignition coil terminal. The terminal cylinder numbers are identified on the ignition coil pack. Ensure that both coil boot retainer locking tabs have engaged. 3. Remove the wire retaining brackets from the old wiring set and install the brackets on the new wires in the same position. Install the wires and retaining brackets on the engine. 4. Connect the wires to the proper Spark plugs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications TIGHTENING SPECIFICATIONS Coilpack mounting screw .......................................................................................................................................................... 44-62 In-lb (5-7 N-m) Coilpack bracket ............................................................................................... .................................................................... 19-24 Ft-lb (26-32 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3538 Coil Pack Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3539 Ignition Coil: Description and Operation Ignition Coil PURPOSE The Electronic Ignition-High Data Rate System (EI) coils provide high voltage needed to jump the gap of the spark plugs and ignite the air/fuel mixture. CONSTRUCTION The coil pack contains multiple coils. Each coil within a coil pack contains a primary and secondary circuit. Primary Windings The windings in the primary circuit is wound on a silicon steel core bobbin. The primary circuit grounds use the same ground through the DIS module. Secondary Windings The winding in the secondary circuit is on a segmented bobbin. The secondary winding uses smaller gauge wire and more turns than the primary circuit. The secondary high tension towers are connected in pairs. OPERATION The ignition coil fires two spark plugs simultaneously, one on the compression stroke and one on the exhaust stroke. Effective Spark When a piston is on compression stroke, most of the ignition coil's available current jumps the gap of the spark plug firing from the center electrode to side electrode, because the resistance is low. Wasted Spark When the companion piston is on exhaust stroke, the spark is wasted. Very little coil energy is wasted. The companion plug fires from the side electrode to the center electrode. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3540 Ignition Coil: Service and Repair Coil Pack Assembly REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the coil pack. 3. Remove the spark plug wires by squeezing the locking tabs to release the coil boot retainers. 4. If vehicle is equipped with air conditioning, remove the air conditioning tube to plenum bolt and move the tube enough to gain access to the upper coil pack bolts. 5. Remove the coil pack mounting screws and remove the coil pack. INSTALLATION 1. Install the coil pack and mounting screws. 2. Tighten to 44-62 lb. in. (5-7 N-m). 3. If vehicle is equipped with air conditioning, reposition the air conditioning tube and replace the bolt. 4. Connect the spark plug wires and electrical connector to the coil pack. 5. Connect the negative battery cable. NOTE: When the battery has been disconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Ignition Control Module: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3545 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3546 Ignition Control Module: Technical Service Bulletins Ignition Control Module - Connector Update Article No. 94-7-8 WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR - FORMERLY CALLED ELECTRONIC DISTRIBUTORLESS IGNITION SYSTEM (EDIS) CONNECTOR - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, GRAND MARQUIS, MARK VIII, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Beginning 1/3/94 revised design ICM connectors are being used after the old style connectors are exhausted. The revised connector has a new seal and new design for better retention. Although the connectors are interchangeable, they pull apart differently. ACTION: If service is required, be aware of the new design when taking the ICM connector apart. ^ The previous style connector had a split beam that had to be pushed "down" while the connector was being pulled off. The word "PUSH" is embossed on the end of the split beam, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3547 ^ The revised style connector has a beam (not split) that must be pried "up", and then pulled off, Figure 2. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3548 Ignition Control Module: Specifications TIGHTENING SPECIFICATIONS ICM mounting screw ............................................................................................................................ ................................... 27-35 lb. in. (3-4 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3549 Ignition Control Module: Locations IGNITION CONTROL MODULE (ICM) LOCATION On RH front corner of engine compartment, left of headlamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3550 Ignition Control Module (ICM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3551 Ignition Control Module: Description and Operation EDIS Module PURPOSE The Electronic Distributorless Ignition System (EI), formerly (EDIS)module's primary function is to deliver full energy spark at a crank angle targeted by the Powertrain Control Module (PCM) and to provide the PCM with crankshaft position information. DESCRIPTION The EI control module is a twelve pin custom microprocessor-based thick film module. Although each engine is very different in size and structure, ICM's for each engine are very similar. With the exception of some pin assignments, basic operation of the EI systems for the different engines is identical. OPERATION The EI control module (ICM) receives input from the Variable Reluctance Sensor (VRS) style Crankshaft Position (CKP) Sensor in order to identify the passing of the missing tooth on the VRS trigger wheel. Synchronization The module is said to be "synchronized" when the missing tooth is found. Synchronization is essential to the ICM in order to track the angular position of the crankshaft relative to a fixed reference and when it should fire the proper coil. Profile Ignition Pickup Profile Ignition Pickup (PIP) output is synthesized by the ICM using input from the VRS signal. The PIP signal generated by the ICM indicates engine speed and crankshaft position to the PCM. The PIP signal is used by the PCM so that it can enable fuel and spark functions and generate a Spark Angle Word (SAW) signal. Spark Angle Word The SAW signal provides spark targeting information to the ICM. By decoding the SAW signal and using the information it receives from the VRS, the ICM turns the coils on and off at correct times and in proper sequence. The EI system operates at a high data rate so it can fire sparks more accurately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3552 Ignition Control Module: Service and Repair Ignition Module REMOVAL 1. Disconnect both battery cables, then remove the battery from the vehicle. 2. Disconnect the electrical connector from the ignition module. NOTE: To disconnect the module connector, push on the connector where it says PUSH, then slide the connector from the module. 3. Remove the ignition module retaining bolt and remove the module by sliding the assembly up until it is released from the teardrop shaped hole in the sheet metal. INSTALLATION 1. Place the module on the sheet metal so the retaining rivet passes through the hole, then slide the module down into position. 2. Install the retaining bolt bolt, torquing to 22-31 lb-in (2.2-3.5 Nm). 3. Connect the electrical connector to the module. 4. Install the battery and cables. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Locations Ignition Timing Connector: Locations Connector Location The SPOUT connector shorting bar (C107), is located at the RF corner of the engine compartment, near EDIS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation Ignition Timing Connector: Description and Operation SPOUT / SAW Connector Operation Spout/SAW Connector DESCRIPTION The Spark Angle Word (SAW),or Spark Output (SPOUT) connector is used to open and close the circuit between the Powertrain Control Module (PCM)and the Ignition Control Module (ICM) for checking base timing. OPERATION When the SPOUT or SAW connector is inserted in the harness connector, the ICM operates according to PCM timing data (computed timing). When the SPOUT or SAW connector is removed from the harness connector, the ICM operates on the Profile Ignition Pickup (PIP) signal only (base timing). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation > SPOUT / SAW Connector Operation > Page 3558 Ignition Timing Connector: Description and Operation Octane Adjustment Switch Operation In-line Connector With Shorting Bar PURPOSE The octane adjustment switch is used to retard the ignition timing approximately three degrees to reduce detonation due to use of lower grade fuels. OPERATION When the switch jumper is INSTALLED, the computed timing is normal. With the jumper REMOVED, the timing computed is retarded approximately three degrees. This is done to allow for optimum spark advance for effective combustion of the air/fuel mixture. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Ignition Control Module: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3564 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3565 Ignition Control Module: Technical Service Bulletins Ignition Control Module - Connector Update Article No. 94-7-8 WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR - FORMERLY CALLED ELECTRONIC DISTRIBUTORLESS IGNITION SYSTEM (EDIS) CONNECTOR - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, GRAND MARQUIS, MARK VIII, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Beginning 1/3/94 revised design ICM connectors are being used after the old style connectors are exhausted. The revised connector has a new seal and new design for better retention. Although the connectors are interchangeable, they pull apart differently. ACTION: If service is required, be aware of the new design when taking the ICM connector apart. ^ The previous style connector had a split beam that had to be pushed "down" while the connector was being pulled off. The word "PUSH" is embossed on the end of the split beam, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 3566 ^ The revised style connector has a beam (not split) that must be pried "up", and then pulled off, Figure 2. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3567 Ignition Control Module: Specifications TIGHTENING SPECIFICATIONS ICM mounting screw ............................................................................................................................ ................................... 27-35 lb. in. (3-4 N-m) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3568 Ignition Control Module: Locations IGNITION CONTROL MODULE (ICM) LOCATION On RH front corner of engine compartment, left of headlamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3569 Ignition Control Module (ICM) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3570 Ignition Control Module: Description and Operation EDIS Module PURPOSE The Electronic Distributorless Ignition System (EI), formerly (EDIS)module's primary function is to deliver full energy spark at a crank angle targeted by the Powertrain Control Module (PCM) and to provide the PCM with crankshaft position information. DESCRIPTION The EI control module is a twelve pin custom microprocessor-based thick film module. Although each engine is very different in size and structure, ICM's for each engine are very similar. With the exception of some pin assignments, basic operation of the EI systems for the different engines is identical. OPERATION The EI control module (ICM) receives input from the Variable Reluctance Sensor (VRS) style Crankshaft Position (CKP) Sensor in order to identify the passing of the missing tooth on the VRS trigger wheel. Synchronization The module is said to be "synchronized" when the missing tooth is found. Synchronization is essential to the ICM in order to track the angular position of the crankshaft relative to a fixed reference and when it should fire the proper coil. Profile Ignition Pickup Profile Ignition Pickup (PIP) output is synthesized by the ICM using input from the VRS signal. The PIP signal generated by the ICM indicates engine speed and crankshaft position to the PCM. The PIP signal is used by the PCM so that it can enable fuel and spark functions and generate a Spark Angle Word (SAW) signal. Spark Angle Word The SAW signal provides spark targeting information to the ICM. By decoding the SAW signal and using the information it receives from the VRS, the ICM turns the coils on and off at correct times and in proper sequence. The EI system operates at a high data rate so it can fire sparks more accurately. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Technical Service Bulletins > Page 3571 Ignition Control Module: Service and Repair Ignition Module REMOVAL 1. Disconnect both battery cables, then remove the battery from the vehicle. 2. Disconnect the electrical connector from the ignition module. NOTE: To disconnect the module connector, push on the connector where it says PUSH, then slide the connector from the module. 3. Remove the ignition module retaining bolt and remove the module by sliding the assembly up until it is released from the teardrop shaped hole in the sheet metal. INSTALLATION 1. Place the module on the sheet metal so the retaining rivet passes through the hole, then slide the module down into position. 2. Install the retaining bolt bolt, torquing to 22-31 lb-in (2.2-3.5 Nm). 3. Connect the electrical connector to the module. 4. Install the battery and cables. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Component Locations On California models equipped with Sequential Fuel Injection (SFI), the Camshaft Position Sensor (CMP), or Cylinder Identification Sensor (CID) is located at the top rear of engine. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal Camshaft Position Sensor: Description and Operation 49 State/Federal NOTE: 49 State/Federal 4.0l utilizes a Multiport Fuel Injection (MFI) system. The fuel injectors are fired in two banks rather than individually, and are synchronized with the Crankshaft Position (CKP) signal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 3578 Camshaft Position Sensor: Description and Operation California Camshaft Sensor PURPOSE In a Sequential Electronic Fuel Injection (SEFI) system each individual fuel injector is energized just prior to the opening of its corresponding intake valve. The Camshaft Position (CMP) sensor is used to identify when number 1 cylinder is on compression stroke and to generate the Cylinder Identification (CID) signal. This CID signal allows the Powertrain Control Module (PCM) to sequence the fuel injectors in the correct order. CONSTRUCTION CMP is a single hall effect magnetic switch, activated by a single vane which is driven by the camshaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > 49 State/Federal > Page 3579 PIP and CMP Signal Comparison OPERATION The camshaft drives a single vane hall effect switch, As the vane passes through the hall effect switch it creates a square wave signal which alternates between battery voltage and 0.0 volts. RELATED DIAGNOSTIC TROUBLE CODES DTC 214 - Cylinder Identification (CID) circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3580 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. 2. Disconnect the engine wiring harness connector at the Camshaft Position (CMP), or Cylinder Identification (CID) sensor. 3. Remove the CMP sensor retaining screws and CMP from synchronizer assembly. NOTE: Prior to the removal of the CMP sensor, set No. 1 cylinder to 0 degrees Top Dead Center (TDC) of the compression stroke. Note the position of the CMP sensor electrical connector. The installation procedure requires that the connector be located in the same position. 4. Remove hold-down clamp. 5. Remove the synchronizer assembly from cylinder block. INSTALLATION 1. Rotate crankshaft until TDC mark on the damper is accessible. If not present, place an additional mark on the damper at 26 degrees After Top Dead Center (ATDC). This position is 34 mm (1.34 in) counterclockwise from the TDC mark. 2. Position No. 1 cylinder to TDC between compression and ignition stroke. (Both intake and exhaust valves must be closed with TDC mark on vibration damper at pointer). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3581 3. Lubricate oil pump drive pinion and O-ring on assembled oil pump drive gear and CMP sensor with SM-2C 1013-A oil. Do not get oil above mounting flange. 4. Align the CMP sensor rotor as shown with the trailing edge of the vane lined up with the short mark at the left-hand side of the plastic window. NOTE: Normal CMP sensor rotation is clockwise viewed from top of CID sensor. 5. Position the sensor above its hole at right angles to the block rear face. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3582 6. Install the assembled CMP sensor and oil pump drive gear into the engine. As the assembly is pushed into place, the camshaft gear will rotate the sensor vane clockwise toward the center window. 7. Rotate the CMP sensor counterclockwise. Install clamp and screw finger-tight. Rotate the sensor back to its position at right angles to the back of the block. 8. Connect the CMP Testing Wiring Harness T94T-50-B or equivalent to the CMP sensor. 9. Connect the CMP Testing Wiring Harness leads: Red harness wire to the battery positive terminal. Black harness wire to battery negative terminal. Voltmeter positive lead to harnesses white lead. Voltmeter negative lead to battery negative terminal. 10. Rotate engine two revolutions to take up slack in timing chain and return to No. 1 cylinder to its compression stroke. 11. Verify that No. 1 cylinder is on its compression stroke. NOTE: No. 1 cylinder must be at 26 degrees ATDC to set CMP sensor. 12. Continue to rotate the crankshaft until the new 26 degrees ATDC mark lines up with the timing pointer. 13. While rotating the CMP sensor, note the exact point where the sensor switches from 0 to 12 volts on the voltmeter. NOTE: The voltmeter will register battery voltage whenever the CMP closes and makes a complete circuit. 14. Rotate the CMP sensor clockwise past the CMP switching point (from 12 to 0 volts). NOTE: The final movement to set the CMP sensor must be in a counterclockwise direction. 15. Rotate the CMP sensor counterclockwise and stop at the exact point the voltmeter switches from 0 to 12 volts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Page 3583 16. Tighten the CMP sensor hold-down bolts to 17-21 Nm (13-15 lb ft) using Sensor Adjusting Wrench T94T-12270-A. 17. Disconnect the testing wiring harness and the voltmeter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications Crankshaft Position Sensor: Electrical Specifications CRANKSHAFT POSITION SENSOR OUTPUT Engine cranking ................................................................................................................................... .............................................. 0.3-1.2 volts AC Engine idling .............................................................. ........................................................................................................................ 2.0-6.0 volts AC Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3588 Crankshaft Position Sensor: Mechanical Specifications TORQUE SPECIFICATION Crankshaft position sensor ...................................................................................................................................................... 9-12 Nm (80-106 in lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 3589 Crankshaft Position Sensor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Ignition System Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3600 Crankshaft Position Sensor: Description and Operation PURPOSE The Crankshaft Position (CKP) sensor provides base timing and engine speed information to the Ignition Control Module (ICM). The ICM supplies this information to the Powertrain Control Module (PCM) as the Profile Ignition Pickup (PIP) signal. The PCM uses this information for fuel injector timing and calculating ignition timing advance and dwell. CONSTRUCTION The CKP is a variable reluctance type sensor that monitors the movement of a 35 tooth wheel located behind the crankshaft pulley. EI Ignition System Oscilloscope Waveform OPERATION As the teeth on the crankshaft pass by the CKP a voltage is induced in the sensor. The CKP output is a spiked sine wave that is proportional to crankshaft speed and position. The missing tooth (36 minus 1) design allows the ICM to synchronize the signal and select the correct coil to fire. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3601 Crankshaft Position Sensor: Testing and Inspection For testing procedures for this component see Ignition System / Testing and Inspection. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 3602 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor REMOVAL 1. Disconnect negative battery cable. 2. Disconnect sensor electrical connector. 3. Remove sensor mounting screws and remove crankshaft position sensor. INSTALLATION 1. Position crankshaft position sensor on engine. 2. Install two sensor attaching screws and tighten screws to 9-12 Nm (80-106 in lb). 3. Route sensor wiring harness and connect electrical connector. 4. Connect negative battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the adaptive strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Description and Operation Hall Effect Sensor: Description and Operation Profile Ignition Pickup The Profile Ignition Pickup (PIP) sensor is a Hall-effect type switch located in the distributor. It sends the Powertrain Control Module (PCM) information on engine speed and crankshaft position. The Hall device operates by the manipulation of magnetic fields. When a rotor vane ENTERS the space between the two halves of the stator pick-up, the magnetic field is altered, turning ON the signal to the PCM. When the vane LEAVES the stator gap, the magnetic field returns to normal, and the signal to the PCM is turned OFF. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 3614 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 3615 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 3621 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 3622 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 3623 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Technical Service Bulletins > Page 3624 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Platinum Spark Plugs - Identification/Location Spark Plug: Technical Service Bulletins Platinum Spark Plugs - Identification/Location Article No. 94-2-8 01/26/94 ^ IGNITION SYSTEM - ELECTRONIC IGNITION (EI) PLATINUM ENHANCED SPARK PLUGS 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L ENGINES ^ ENGINE - 1.9L, 2.3L OHC (TPH), 3.8L, 4.0L - PLATINUM ENHANCED SPARK PLUG LOCATIONS FORD: 1994 ESCORT, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994 COUGAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, EXPLORER, RANGER ISSUE: Three (3) different unique styles of platinum enhanced spark plugs are produced for vehicles with Electronic Ignition (EI). Each style is distinguished by their part number suffix letters. ^ The suffix letter "P" indicates the center electrode is enhanced with platinum. ^ The suffix letter "PG" indicates the ground (side) electrode is enhanced with platinum. ^ The suffix letter "PP" indicates double platinum enhancement on both the ground (side) and center electrode. ACTION: If a spark plug is removed for examination, it must be reinstalled in the same cylinder. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter "PP" as shown on the engine decal. Refer to the following Platinum Enhanced Spark Plug Replacement Chart for correct parts usage. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 499000, 623000, 690000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap Spark Plug: Specifications Spark Plug Gap SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Plug Type .......................................................... ............................................................................................................................. Motorcraft AWSF-42PP Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Gap > Page 3631 Spark Plug: Specifications Tightening Torque SPARK PLUG Electrode Gap ...................................................................................................................................... .................................... 0.052-0.056 in (1.3-1.4 mm) Tightening Torque ............................................. .................................................................................................................................... 7-15 ft lb (9-20 Nm) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3632 Spark Plug: Description and Operation PURPOSE Spark plugs provide the path for secondary ignition system high voltage to flow to ground. OPERATION Voltage arcing between plug center and ground electrode produces the spark to ignite the air/fuel mixture. CONSTRUCTION Many spark plugs are made with an internal resistor, designed to reduce ignition system electrical interference with entertainment systems and computerized devices. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3633 Spark Plug: Testing and Inspection Testing For Spark 1. Remove the spark plug. 2. Connect the spark plug to the spark plug wire. 3. Hold the spark plug with insulated pliers 0.20-0.40 in (5-10 mm) from a ground. 4. Crank the engine and verify that there is a strong blue spark. If there Is no spark, replace the spark plug. Spark Plug 5. Check the following points. If a problem is found, replace the spark plug. ^ Damaged insulation ^ Worn electrodes ^ Carbon deposits. (If cleaning is necessary, use a plug cleaner or a wire brush. Clean the upper insulator also.) ^ Damaged gasket. ^ Burnt condition. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Ignition System > RPM Test Connector <--> [Tachometer Connector] > Component Information > Locations RPM Test Connector: Locations TACHOMETER SERVICE CONNECTOR LOCATION RH rear of engine compartment, near blower motor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3643 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3644 A4LD Automatic Transmission Solenoids: Description and Operation Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions A4LD Automatic Transmission Solenoids: Diagnostic Trouble Code Descriptions Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Symptoms: Failed "ON," vehicle has lack of acceleration performance at start out. Failed "OFF," No 3-4 upshift or 4-3 downshift. Diagnostic Trouble Codes: 566, 3-4 shift solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations > Page 3650 Converter Clutch Override Solenoid: Description and Operation Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Converter Clutch Override Solenoid: Diagnostic Trouble Code Descriptions Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Symptoms: Failed "ON," the torque converter clutch would always be engaged above 30 mph. Failed "OFF," the torque converter clutch will not engage. Diagnostic Trouble Codes: 629, TCC solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3659 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3660 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3661 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3662 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3663 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3664 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3665 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3666 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3677 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3678 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3692 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3693 A4LD Automatic Transmission Solenoids: Description and Operation Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions A4LD Automatic Transmission Solenoids: Diagnostic Trouble Code Descriptions Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Symptoms: Failed "ON," vehicle has lack of acceleration performance at start out. Failed "OFF," No 3-4 upshift or 4-3 downshift. Diagnostic Trouble Codes: 566, 3-4 shift solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations > Page 3699 Converter Clutch Override Solenoid: Description and Operation Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Converter Clutch Override Solenoid: Diagnostic Trouble Code Descriptions Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Symptoms: Failed "ON," the torque converter clutch would always be engaged above 30 mph. Failed "OFF," the torque converter clutch will not engage. Diagnostic Trouble Codes: 629, TCC solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3707 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3708 A4LD Automatic Transmission Solenoids: Description and Operation Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions A4LD Automatic Transmission Solenoids: Diagnostic Trouble Code Descriptions Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Symptoms: Failed "ON," vehicle has lack of acceleration performance at start out. Failed "OFF," No 3-4 upshift or 4-3 downshift. Diagnostic Trouble Codes: 566, 3-4 shift solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations > Page 3714 Converter Clutch Override Solenoid: Description and Operation Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Converter Clutch Override Solenoid: Diagnostic Trouble Code Descriptions Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Symptoms: Failed "ON," the torque converter clutch would always be engaged above 30 mph. Failed "OFF," the torque converter clutch will not engage. Diagnostic Trouble Codes: 629, TCC solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Specifications Band: Specifications Overdrive Band Adjusting Screw Locknut To Case 35-45 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > Low and Reverse Band Band: Description and Operation Low and Reverse Band DESCRIPTION AND OPERATION In reverse and 1st gears, with selector lever in position 1, the reverse band is applied to hold the rear planet carrier by means of the rear clutch drum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > Low and Reverse Band > Page 3722 Band: Description and Operation Overdrive Band DESCRIPTION AND OPERATION In 4th gear, the overdrive band is applied to hold the sun gear of the overdrive planet gear set, by means of the overdrive drum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Description and Operation > Low and Reverse Band > Page 3723 Band: Description and Operation With A4LD/4R44E/4R55E BAND AND CLUTCH APPLICATION Band And Application Chart, (Part 1 Of 2) Band And Application Chart, (Part 2 Of 2) Information on band and clutch application and gear ratios for all possible operating conditions is shown in the image. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > A/T - A4LD Servo Cover Heat Shield Band Apply Servo: Technical Service Bulletins A/T - A4LD Servo Cover Heat Shield Article No. 94-6-16 Date: March 23, 1994 TRANSMISSION - A4LD-SERVO COVER HEAT SHIELD REQUIRED TO AVOID DAMAGING OVERDRIVE AND INTERMEDIATE SERVOS - VEHICLES WITH 4.0L ENGINE LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Damage to overdrive and intermediate servos may occur if the servo heat shield is not reinstalled after servicing A4LD transmissions with 4.0L engines. ACTION: When servicing A4LD transmissions with 4.0L engines that require servo cover heat shield removal, it is necessary that this heat shield be reinstalled to deflect heat generated by the catalytic converter away from the transmission. Failure to do so may result in premature failure of the overdrive, intermediate servos and transmission. PART NUMBER PART NAME CLASS FOTZ-7FO13-A Servo Cover Heat Shield C OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 604000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Page 3728 Band Apply Servo: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Loosen oil pan attaching bolts and allow transmission fluid to drain. 3. Remove oil pan attaching bolts and oil pan. 4. Remove oil filter screen and gasket. 5. Remove low-reverse servo cover retaining screws, then the cover, servo piston, spring, and gasket. INSTALLATION 1. Reverse procedure to install. 2. Torque oil pan attaching bolts to 98-115 in lbs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - A4LD/4R44E/5R55E New Center Support Clutch: Technical Service Bulletins A/T - A4LD/4R44E/5R55E New Center Support Article No. 01/19/98 98-1-12 ^ TRANSMISSION - 4R44E/5R55E - NEW SERVICE PART - CENTER SUPPORT - SERVICE TIP ^ TRANSMISSION - A4LD - NEW SERVICE PART - CENTER SUPPORT - SERVICE TIP FORD: 1985-93 MUSTANG 1987-88 THUNDERBIRD LINCOLN-MERCURY: 1987 COUGAR LIGHT TRUCK: 1985-90 BRONCO II 1985-97 RANGER 1988-97 AEROSTAR 1991-97 EXPLORER ISSUE: A new service Center Support that uses a thrust bearing (# 3 and # 4) in place of thrust washers has been released. The procedure used in determining rear end play and selecting the new Number 4 Thrust Bearing has been revised. ACTION: Use the Instruction Sheet packed with the new thrust bearing center supports to determine rear end play and the correct Number 4 Thrust Bearing. NOTE: REFER TO THE LATEST VERSION SERVICE MANUAL PROCEDURE FOR DISASSEMBLY AND REASSEMBLY OF THE TRANSMISSION AS LISTED IN THE APPROPRIATE MODEL/YEAR SERVICE MANUAL. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 503000, 504000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - A4LD/4R44E/5R55E New Center Support > Page 3733 Clutch: Technical Service Bulletins A/T - E4OD Direct Clutch Plate Usage Chart/Service Tip Article No. 95-25-13 12/18/95 TRANSMISSION - E4OD - DIRECT CLUTCH PLATE USAGE CHART - SERVICE TIP LIGHT TRUCK: 1989-96 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES ISSUE: The direct clutch friction plates in the E4OD transmission have changed for 1996. These revised clutch plates have grooves in the friction material. Refer to Figures 1 and 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > A/T - A4LD/4R44E/5R55E New Center Support > Page 3734 ACTION: If replacement of the direct clutch friction plates is necessary, refer to the Application Chart for correct part usage. Using the incorrect friction plate could result in a shift concern. PART NUMBER PART NAME E9TZ-7B164-D Direct Clutch Plate F6TZ-7B164-B Direct Clutch Plate OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Clutch, A/T Clutch: Description and Operation Clutch, A/T Clutch Application With A4LD/4R44E/4R55E CLUTCH AND BAND APPLICATION Band And Application Chart, (Part 1 Of 2) Band And Application Chart, (Part 2 Of 2) Information on band and clutch application and gear ratios for all possible operating conditions is shown in the image. Clutch Drum Assembly With A4LD/4R44E/4R55E DESCRIPTION AND OPERATION The forward clutch is connected to the intermediate shaft by means of splines. The outer splines of the forward clutch hub mesh with the friction plates of the reverse and high clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Clutch, A/T > Page 3737 Clutch: Description and Operation Forward Clutch DESCRIPTION AND OPERATION The forward clutch is engaged in all forward gears. The clutch engages the intermediate shaft with the ring gear of the forward planetary gear set. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > Clutch, A/T > Page 3738 Clutch: Description and Operation Overdrive Clutch Overdrive Clutch WITH A4LD/4R44E/4R55E DESCRIPTION AND OPERATION The overdrive one-way clutch locks in direction of engine rotation and the intermediate shaft. In opposite direction of engine rotation, the clutch freewheels without the effect of engine braking. With A4LD/4R44E/4R55E DESCRIPTION AND OPERATION The overdrive clutch is engaged in 1st and 2nd gear with selector lever in position 1 and 2. It also engages the overdrive sun gear and the input with the intermediate shaft. In this case, the O/D one-way clutch is engaged and on coasting engine braking takes place. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch Clutch: Service and Repair Coast Clutch DISASSEMBLE Exploded View Of Coast (overdrive) Clutch 1. Remove pressure plate retainer ring, then the plate pack. 2. Inspect steel clutch plates and clutch lining plates for wear, damage, or effects of overheating, replacing entire set if necessary. NOTE: If new plates are to be used, immerse them in transmission fluid for 30 minutes before assembly. Clutch Spring And Compression Spring Retainer Replacement 3. Using clutch spring compressor tool No. T65L-77515-A or equivalent, compress clutch compression springs, remove retaining ring, and carefully release pressure on spring, then remove spring and compression spring retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3741 Removing Reverse/High Clutch Piston Or Air Testing Assembled Reverse/High Clutch 4. Apply no more than 20 psi air pressure to blow out clutch piston as shown in the Removing Coast (Overdrive) Clutch Piston Or Air Testing Assembled Overdrive Clutch image, using finger to close off opposite hole. ASSEMBLE 1. Install new seal rings on clutch piston. 2. Carefully install clutch piston into clutch body. 3. Install compression spring and spring retainer, compress springs using clutch spring compressor and install retaining ring, as shown in the Clutch Spring And Compression Spring Retainer Replacement image. 4. Install clutch plates beginning with a steel plate, then alternate friction, steel, friction, and install pressure plate and retaining clip. 5. Using feeler gauge, check clearance between retaining ring and pressure plate, pushing downward on plates while checking clearance. 6. If clearance is not 0.039-0.067 inch install corrective selective retaining ring. Retaining rings are available in thicknesses of 0.0539, 0.0681, 0.0819 and 0.0961 inch. 7. Block hole with finger to prevent air leakage and ensure piston applies when pressurized and releases when air is removed, as shown in the Removing Coast (Overdrive) Clutch Piston Or Air Testing Assembled Overdrive Clutch image. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3742 Clutch: Service and Repair Direct Clutch DISASSEMBLY Exploded View Of Reverse High Clutch 1. Remove pressure plate retainer ring, then the plate pack. 2. Inspect steel clutch plates and clutch lining plates for wear, damage, or effects of overheating, replacing entire set if necessary. NOTE: If new plates are to be used, immerse them in transmission fluid for 30 minutes before assembly. Clutch Spring And Compression Spring Retainer Replacement 3. Using clutch spring compressor tool No. T65L-77515-A or equivalent, compress clutch compression springs, remove retaining ring, and carefully release pressure on spring, then remove spring and compression spring retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3743 Removing Reverse/High Clutch Piston Or Air Testing Assembled Reverse/High Clutch 4. Apply no more than 20 psi air pressure to blow out clutch piston as shown in the Direct Clutch (reverse/high) Piston Removal Or Clutch Assembly Air Test image, using finger to close off opposite hole. ASSEMBLY 1. Install new seal rings on clutch piston. 2. Carefully install clutch piston into clutch body. 3. Install compression spring and spring retainer, compress springs using clutch spring compressor and install retaining ring, as shown in the Clutch Spring And Compression Spring Retainer Replacement image. 4. Install clutch plates beginning with a steel plate, then alternate friction and steel plates. 5. Install pressure plate and secure with retaining ring. 6. Using feeler gauge, check clearance between retaining ring and pressure plate, pushing downward on plates while checking clearance. 7. If clearance is not 0.051-0.079 inch, install corrective selective retaining ring. Retaining rings are available in thicknesses of 0.0539, 0.0681, 0.0819, and 0.0961 inch. 8. Block hole with finger to prevent air leakage, then ensure piston applies when pressurized and releases when air is stopped, as shown in the Direct Clutch (reverse/high) Piston Removal Or Clutch Assembly Air Test image. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3744 Clutch: Service and Repair Forward Clutch DISASSEMBLE Exploded View Of Forward Clutch 1. Remove pressure plate retainer ring, then the plate pack. 2. Inspect steel clutch plates and clutch lining plates for wear, damage, or effects of overheating, replacing entire set if necessary. NOTE: If new plates are to be used, immerse them in transmission fluid for 30 minutes before assembly. Clutch Spring And Compression Spring Retainer Replacement 3. Using clutch spring compressor tool No. T65L-77515-A or equivalent, compress clutch compression springs, remove retaining ring, and carefully release pressure on spring, then remove spring and compression spring retainer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3745 Removing Forward Clutch Piston Or Air Testing Assembled Forward Clutch 4. Install center support on forward clutch cylinder, then apply no more than 20 psi air pressure to left port in center support to force piston assembly from clutch cylinder as shown in the Forward Clutch Piston Removal Or Forward Clutch Assembly Air Test image, using finger to close off opposite hole. ASSEMBLE 1. Install new seal rings on clutch piston. 2. Carefully install clutch piston into clutch body. 3. Install compression spring and spring retainer, compress springs using clutch spring compressor and install retaining ring, as shown in the Clutch Spring And Compression Spring Retainer Replacement image. 4. Install clutch plates beginning with a steel plate, then alternate friction, steel, friction, and so on, then install pressure plate and retaining ring. 5. Using feeler gauge, check clearance between retaining ring and pressure plate, pushing downward on plates while checking clearance. 6. If clearance is not 0.055-0.083 inch install corrective selective retaining ring. Retaining rings are available in thicknesses of 0.0539, 0.0681, 0.0819 and 0.0961 inch. 7. Install center support on forward clutch cylinder, as shown in the Forward Clutch Piston Removal Or Forward Clutch Assembly Air Test image, then apply no more than 20 psi air pressure to left port in center support to check piston application. Piston must apply when pressurized and release when air is removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Coast Clutch > Page 3746 Clutch: Service and Repair One-Way Clutch, A/T REMOVAL NOTE: Models with 4.0L engines use a sprag type one-way clutch that should not be disassembled. 1. Remove snap ring using a screwdriver, then lift out cage with springs and bearing as an assembly. 2. Inspect inner and outer races for scores or damaged surfaces where rollers contact races. 3. Inspect rollers and springs for excessive wear or damage, then the spring and roller cage for bent or damaged spring retainers. INSTALLATION 1. Install cage with springs, then insert bearing rollers one by one and install snap ring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Install scribe marks on propeller shaft end yoke and rear axle companion flange, then remove propeller shaft. 3. Support transmission with suitable jack. 4. Remove speedometer cable from extension housing. 5. Remove bolts or nuts attaching rear support to crossmember. 6. Raise transmission slightly and remove rear support from extension housing. 7. Loosen extension housing attaching bolts and allow transmission to drain. 8. Remove bolts and the extension housing. INSTALLATION 1. Reverse procedure to install, noting the following: a. Use new extension housing gasket. b. Ensure parking pawl actuating rod is correctly seated in guide cup bore. c. Torque attaching bolts to 27-39 ft lbs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 3757 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 3758 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications TYPE MA CAPACITY, Initial Refill*: A4LD 3.0 qt (US) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 3761 Fluid - A/T: Specifications Automatic Transmission Capacity 9.7 qt (US) Approximate. Make final check w/dipstick. Fluid Type Mercon(r) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check Fluid - A/T: Testing and Inspection Fluid Level Check CHECKING OIL LEVEL 1. With transmission in Park, engine at curb idle RPM, foot brakes applied, and vehicle on a level surface, move transmission selector lever through each range. Allow time in each range for transmission to engage, then return to Park and apply parking brake fully. NOTE: If vehicle has been operated for an extended period at high speed, in city traffic during hot weather, or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking. NOTE: Vehicles equipped with 4X4 applications must have the 4X4 shift selector in any position other than neutral. CAUTION: Your vehicle should not be driven if the fluid level is below the bottom hole on the dipstick and outside temperatures are above 10°C (50°F). 2. Clean all dirt from transmission dipstick cap. 3. Pull dipstick out of filler tube, wipe clean, and push dipstick back all the way into the filler tube, ensuring it is full seated. 4. Pull dipstick out of tube again and check fluid level as follows: a. With transmission at operating temperature, 150° F-170° F, fluid level should be within the cross hatched area. b. With transmission at room temperature, 70° F-95° F, fluid should be between middle and top holes. 5. If it is necessary to add fluid, use only Dexron II or equivalent. CAUTION: The use of fluid other than that specified could result in transmission malfunction and/or failure. 6. Install dipstick, ensuring it is fully seated in tube. Adding Fluid 1. The fluid type is stamped on the dipstick. Before adding any fluid, be sure that the correct type will be used. 2. Add fluid in .25L (1/2 pint) increments through the filler tube to bring the level to the correct area on the dipstick. If an overfill occurs, excess fluid should be removed. Overfill can cause the fluid to foam and spill out through the transmission vent resulting in a transmission malfunction. Undertill can result in transmission loss of engagement or slipping. This condition is most evident in cold weather or when the vehicle is parked or being driven on a hill. If the transmission fluid level is checked when the fluid is at room temperature the dipstick could indicate that fluid should be added if the dipstick is misread. If fluid is added at this time, an overfill condition could result when the fluid reaches operating temperatures of 66° C-77°C (150°F-170°F) (dipstick hot to touch). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check > Page 3764 Fluid - A/T: Testing and Inspection Transaxle Fluid Cooler Flow Test TRANSMISSION FLUID COOLER CHECK 1. Ensure linkage is properly adjusted and fluid level and control pressure are within specifications. 2. Remove transmission dipstick from filler tube and insert funnel in tube. 3. Raise and support vehicle. 4. Remove cooler return line from its fitting in the case, attach a hose to cooler return line and fasten free end of hose in funnel installed in filler tube. 5. Start engine and set idle at 1,000 RPM with transmission in Neutral. 6. Observe fluid flow at funnel. When flow is constant, it should be liberal. If there is not a liberal flow at 1,000 RPM in Neutral, low pump capacity, main circuit system leakage, stuck converter charge relief valve, or cooler system restriction is indicated. 7. To separate transmission trouble from cooler system trouble, observe flow at transmission case converter-out fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Fluid Level Check > Page 3765 Fluid - A/T: Testing and Inspection Transmission Fluid Cooler Check TRANSMISSION FLUID COOLER CHECK 1. Ensure linkage is properly adjusted and fluid level and control pressure are within specifications. 2. Remove transmission dipstick from filler tube and insert funnel in tube. 3. Raise and support vehicle. 4. Remove cooler return line from its fitting in the case, attach a hose to cooler return line and fasten free end of hose in funnel installed in filler tube. 5. Start engine and set idle at 1,000 RPM with transmission in Neutral. 6. Observe fluid flow at funnel. When flow is constant, it should be liberal. If there is not a liberal flow at 1,000 RPM in Neutral, low pump capacity, main circuit system leakage, stuck converter charge relief valve, or cooler system restriction is indicated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Page 3766 Fluid - A/T: Service and Repair NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid. FLUID CHANGE NOTE: Normal maintenance and lubrication requirements do not necessitate periodic fluid changes. If a major failure has occurred in the transmission, it will have to be removed for service. At that time the converter, transmission cooler, and cooler lines must be flushed to remove any dirt. If vehicle accumulates 5,000 or more miles per month or is used in continuous stop and go service, change fluid every 30,000 miles as described. Procedures for partial drain and refill, due to in-vehicle service operation, are as follows: 1. Loosen pan attaching bolts and drain fluid. 2. Remove and thoroughly clean pan and screen, discarding pan gasket. 3. Place new gasket on pan and install pan on transmission. 4. Add 3 quarts of fluid to transmission through filler tube. 5. Check fluid level following room normal operating checking procedures. NOTE: When filling a dry transmission and converter, approximate retill capacity is 9 quarts. Make final check using normal operating temperature checking procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 3771 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 3772 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 97-22-4 > Oct > 97 > A/T Torque Converter Slip/DTC 628/P0741 Set Fluid Pump: Customer Interest A/T - Torque Converter Slip/DTC 628/P0741 Set Article No. 97-22-4 10/27/97 TRANSMISSION - A4LD, 4R44E/4R55E, 5R55E - TORQUE CONVERTER SLIP - DIAGNOSTIC TROUBLE CODE (DTC) 628 OR P0741 STORED IN MEMORY FORD: 1985-93 MUSTANG 1987-88 THUNDERBIRD LINCOLN-MERCURY: 1988 COUGAR LIGHT TRUCK: 1985-90 BRONCO II 1985-97 RANGER 1987-97 AEROSTAR 1991-97 EXPLORER ISSUE: Some vehicles may experience excessive torque converter slippage, torque converter not engaging, or Diagnostic Trouble Code (DTC) 628 or P0741 stored in memory. This may be caused by damage to the fluid pump support seal and/or to the groove on the pump where the seal is located. ACTION: Inspect the fluid pump seal for damage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Follow normal diagnostic procedures as listed in the appropriate Service Manual. 2. Inspect the fluid pump support for damage. If damaged, also inspect the fluid pump support seal groove on the pump. 3. If the groove is damaged, replace the pump. 4. If the groove is not damaged, replace the fluid pump support seal with a redesigned Seal (F77Z-7L323-AA). Refer to Figure 1. 5. Do not replace the torque converter unless it is damaged or fails the criteria listed in the appropriate Service Manual and/or refer to TSB 96-26-12. PART NUMBER PART NAME F77Z-7L323-AA Fluid Pump Support Seal OTHER APPLICABLE ARTICLES: 96-26-12 WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 97-22-4 > Oct > 97 > A/T Torque Converter Slip/DTC 628/P0741 Set > Page 3781 OASIS CODES: 501000, 502000, 504000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 97-22-4 > Oct > 97 > A/T - Torque Converter Slip/DTC 628/P0741 Set Fluid Pump: All Technical Service Bulletins A/T - Torque Converter Slip/DTC 628/P0741 Set Article No. 97-22-4 10/27/97 TRANSMISSION - A4LD, 4R44E/4R55E, 5R55E - TORQUE CONVERTER SLIP - DIAGNOSTIC TROUBLE CODE (DTC) 628 OR P0741 STORED IN MEMORY FORD: 1985-93 MUSTANG 1987-88 THUNDERBIRD LINCOLN-MERCURY: 1988 COUGAR LIGHT TRUCK: 1985-90 BRONCO II 1985-97 RANGER 1987-97 AEROSTAR 1991-97 EXPLORER ISSUE: Some vehicles may experience excessive torque converter slippage, torque converter not engaging, or Diagnostic Trouble Code (DTC) 628 or P0741 stored in memory. This may be caused by damage to the fluid pump support seal and/or to the groove on the pump where the seal is located. ACTION: Inspect the fluid pump seal for damage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Follow normal diagnostic procedures as listed in the appropriate Service Manual. 2. Inspect the fluid pump support for damage. If damaged, also inspect the fluid pump support seal groove on the pump. 3. If the groove is damaged, replace the pump. 4. If the groove is not damaged, replace the fluid pump support seal with a redesigned Seal (F77Z-7L323-AA). Refer to Figure 1. 5. Do not replace the torque converter unless it is damaged or fails the criteria listed in the appropriate Service Manual and/or refer to TSB 96-26-12. PART NUMBER PART NAME F77Z-7L323-AA Fluid Pump Support Seal OTHER APPLICABLE ARTICLES: 96-26-12 WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 97-22-4 > Oct > 97 > A/T - Torque Converter Slip/DTC 628/P0741 Set > Page 3787 OASIS CODES: 501000, 502000, 504000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Testing and Inspection Governor: Testing and Inspection GOVERNOR TEST NOTE: The governor can be checked at the same time as the Control Pressure Test is performed and in the same manner. 1. Raise and support rear of vehicle, then disconnect and plug the vacuum line to the vacuum diaphragm unit. 2. Connect the line from the distributor tester to the vacuum diaphragm unit and install automatic transmission tester. CAUTION: Never exceed 60 MPH speedometer speed. 3. Place transmission in D2, with no load on engine, and apply 10 inches of vacuum to vacuum diaphragm unit. 4. Increase speed slowly and watch speedometer, noting speed at which control pressure cutback occurs. It should occur between 8 and 12 mph. 5. Decrease vacuum at vacuum diaphragm to 0.0-2.0 inches. Control pressure cutback should occur between 10 and 14 mph. NOTE: After each test, move selector to N and run engine at 1,000 RPM to cool transmission. 6. The governor is good if cutback occurs within specifications. If cutback does not occur within specifications, check shift speed to verify that it is the governor and not a stuck cutback valve, then repair or replace governor as necessary. 7. To separate transmission trouble from cooler system trouble, observe flow at transmission case converter-out fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal and Installation Governor: Service and Repair Removal and Installation REMOVAL NOTE: Refer to Technical Service Bulletins (TSB) for governor seal ring replacement information. 1. Remove extension housing. 2. Remove governor body to oil collector body attaching bolts. 3. Remove governor body, valve, spring, and weight from collector body. NOTE: Components are not retained once governor body to oil collector body attaching bolts have been removed. It is therefore necessary to hold the governor body and components while removing or installing. INSTALLATION 1. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal and Installation > Page 3793 Governor: Service and Repair Disassembly and Assembly DISASSEMBLY NOTE: Refer to Technical Service Bulletins (TSB) for governor seal ring replacement information. Exploded View Of Oil Collector And Governor Bodies 1. Remove governor body to oil collector body attaching bolts. NOTE: When governor body attaching bolts are removed, the governor components are no longer retained in position to the governor body. Care must be taken not to drop the governor body and components when the attaching bolts are removed. 2. Remove governor components from governor body. 3. Remove counterweight. 4. Clean all parts, replacing any that are worn or damaged. ASSEMBLY 1. Assemble outer weight spring and primary valve in governor body. 2. Assemble governor body and counterweight to oil collector body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Description and Operation Parking Pawl: Description and Operation WITH A4LD/4R44E/4R55E DESCRIPTION AND OPERATION Allows the output shaft to be mechanically locked by the parking pawl anchored in the case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation Planetary Gears: Description and Operation DESCRIPTION AND OPERATION Three gear sets are used to provide the four forward speeds and reverse. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > Page 3800 Planetary Gears: Service and Repair WITH A4LD/4R44E/4R55E ASSEMBLE NOTE: Refer to the Technical Service Bulletins (TSB) section for related information. Exploded View Of Forward Gear Train Assembly 1. Assemble forward clutch to reverse/high clutch, positioning No. 5 thrust washer between them. 2. Assemble forward planet gear carrier to internal gear with needle bearing thrust washer No. 7 between them. 3. On models with 4.0L engine, position forward clutch thrust washer on forward planet carrier hub, then the No. 6 needle bearing on forward clutch cylinder internal thrust surface. 4. On models except 4.0L engine, position integral thrust washer on forward planet gear carrier hub. 5. On all models, install front planet assembly into forward clutch. 6. Position needle bearing washer into forward planet gear carrier and install clutch hub and sun gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair With A4LD/4R44E/4R55E REMOVAL 1. Raise and support vehicle. 2. Install scribe marks on propeller shaft end yoke and rear axle companion flange, then remove propeller shaft. Extension Housing Rear Seal & Bushing Replacement 3. Using extension housing seal remover tool No. T71P-7657-A or equivalent, remove oil seal. 4. Using extension housing bushing remover tool No. T77L-7697-E or equivalent, remove extension housing bushing. INSTALLATION 1. Using extension housing bushing replacer tool No. T77L-7697-F or equivalent, install new extension housing bushing. 2. Inspect sealing surface of universal joint yoke for scoring, replacing yoke as necessary. 3. Inspect counterbore of housing for burrs, removing as necessary. 4. Using extension housing seal replacer tool No. T74P-77052-A or equivalent, install new oil seal. Coat inside diameter at end of rubber boot portion of seal and the front universal joint spline with suitable lubricant. 5. Install propeller shaft, aligning scribe marks, then lower vehicle and check transmission fluid level, adding fluid as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3812 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3813 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3820 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 3821 A4LD Automatic Transmission Solenoids: Description and Operation Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions A4LD Automatic Transmission Solenoids: Diagnostic Trouble Code Descriptions Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Symptoms: Failed "ON," vehicle has lack of acceleration performance at start out. Failed "OFF," No 3-4 upshift or 4-3 downshift. Diagnostic Trouble Codes: 566, 3-4 shift solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Adjustments Shift Linkage: Adjustments ADJUST 1. Place selector lever in Overdrive position, then hang a 3 pound weight on end selector lever. 2. Raise and support vehicle. 3. Release lock tab on top side of cable by pushing down on two tangs, then disconnect shift cable from manual lever. 4. On Explorer and Ranger models, position manual lever in Overdrive position by moving lever all the way rearward (counterclockwise), then forward three detents (clockwise). 5. On Aerostar models, position manual lever all the way forward (counterclockwise), then rearward three detents (clockwise). 6. On all models, connect shift cable to manual lever, then completely push down lock tab, ensuring it fully engages. 7. Ensure shift cable is clipped to floorpan, then lower vehicle. 8. Adjust shift indicator pointer while transmission is still in Overdrive position. 9. Remove weight from selector lever, then check for proper engagement of all gears, including Park. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Service and Repair > Transmission Out of Vehicle Shift Linkage: Service and Repair Transmission Out of Vehicle REMOVAL NOTE: The automatic transmission linkage system incorporates a polyurethane plastic grommet to connect the various rods, levers, and adjusting stud. Whenever a rod is disconnected from a grommet type connector, the old grommet must be removed and a new one installed. Shift Linkage Grommet Out Of Vehicle Replacement 1. Place lower jaw of shift linkage insulator T67P-7341-A or equivalent, between lever and rod, then position stop pin against end of control rod and force rod out of grommet. 2. Remove grommet from lever by cutting off large shoulder with sharp knife. INSTALLATION 1. Adjust stop pin to 1/2 inch and coat outside of grommet with suitable multi purpose lubricant. 2. Place a new grommet on the stop pin and force it into the lever hole, then turn grommet several times to ensure it is properly seated. 3. Squeeze rod into bushing until stop washer seats against grommet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Service and Repair > Transmission Out of Vehicle > Page 3829 Shift Linkage: Service and Repair Transmission In Vehicle REMOVAL NOTE: The automatic transmission linkage system incorporates a polyurethane plastic grommet to connect the various rods, levers, and adjusting stud. Whenever a rod is disconnected from a grommet type connector, the old grommet must be removed and a new one installed. Shift Linkage Grommet In-vehicle Replacement 1. Disconnect linkage from grommet, then position shift linkage grommet remover T84P-7341-A or equivalent, and rotate screw in tool until grommet is forced out of lever. 2. Adjust stop on shift linkage grommet replacer tool No. T84P-7341-B or equivalent, to 1/2 inch, then coat outside of new grommet with suitable multi-purpose lubricant. INSTALLATION 1. Position grommet on lever and install grommet replacer on lever, rotate screw to force grommet into position. Turn grommet several times to ensure it is fully seated. 2. Connect linkage and tighten attaching nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Modulator > Component Information > Service and Repair Shift Modulator: Service and Repair Vacuum Diaphragm Assembly Note: This procedure was taken from the Disassembly and Assembly articles of the A4LD Automatic Transmission. For additional information to access this assembly refer to the Disassembly and Assembly procedures. See: Service and Repair Removal Use a 10mm socket to remove one (M6 x 12mm) screw and retainer. Remove the vacuum diaphragm assembly and throttle valve actuator rod. Verify that the throttle valve moves freely using flat external snap ring pliers. Then remove the valve with the pliers. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Modulator > Component Information > Service and Repair > Page 3833 NOTE: All 4 x 4 and 4.0L applications will use a studded bolt (M6 x 1.0). Tighten stud to 12-16 N-m (106-142 in-lb), screw to 9-12 N-m (80-106 in-lb). CAUTION: Make sure the valve moves freely in the bore. Install throttle valve, actuating rod, vacuum diaphragm and retaining clamp. Hold in position by tightening M6 x 12mm screw with a 10mm wrench. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure Torque Converter: Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3838 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3839 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3840 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3841 Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3842 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 3843 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 3844 Torque Converter: Testing and Inspection TORQUE CONVERTER CLUTCH TEST NOTE: This test should be performed on the road. If performed on the hoist the technician may not feel the torque converter clutch solenoid engage. NOTE: The torque converter clutch solenoid is labeled "CCO" on the transmission tester overlay. CAUTION: Do not depress torque converter clutch switch with transmission in gear and the vehicle at a stop. Damage to torque converter clutch may result. NOTE: Engine coolant temperature must be above 128° and below 240° F. This temperature can be obtained after approximately 15 minutes of highway driving. Since most converter clutch shifts are difficult to feel, a tachometer and/or vacuum gauge must be connected to engine. 1. Accelerate vehicle to 88km/h (55 mph) and allow vehicle to upshift into third gear. Hold speed steady and depress the torque converter clutch switch. Does the torque converter (7902) engage? Does the engine rpm drop? Did the torque converter clutch solenoid activate/deactivate? Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 3845 Torque Converter: Adjustments Torque Converter End Play SPECIAL SERVICE TOOL(S) REQUIRED Description ........................................................................................................................................... ....................................................... Tool Number End Play Checking Tool ........................................ ...................................................................................................................................... T80L-7902-A 1. Insert torque converter End Play Checking Tool into the converter impeller hub, until it bottoms. 2. Expand sleeve in the turbine spline by tightening the threaded inner post until the tool is securely locked in the spline. 3. Attach Dial Indicator With Bracketry TOOL-4201-C or equivalent to the torque converter End Play Checking Tool. Position the indicator button on the converter impeller housing, and set the dial face at 0 (zero). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 3846 4. Lift tool upward as far as it will go and note indicator reading. The indicator reading is the total end play which the turbine and stator share. Replace the converter unit if the total end play exceeds the limits. Refer to Specifications at the end of this article. 5. Loosen threaded inner post to free tool, and remove the tool from the torque converter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 3847 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations > Page 3851 Converter Clutch Override Solenoid: Description and Operation Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Converter Clutch Override Solenoid: Diagnostic Trouble Code Descriptions Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Symptoms: Failed "ON," the torque converter clutch would always be engaged above 30 mph. Failed "OFF," the torque converter clutch will not engage. Diagnostic Trouble Codes: 629, TCC solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 3858 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 3859 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 3860 Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 3861 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 3862 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 3863 Transmission Cooler: Testing and Inspection Transmission Fluid Cooler Flow Check NOTE: The transmission linkage/cable adjustment, fluid level, and line pressure must be within specification before performing this test. Refer to service procedures as outlined. 1. Remove transmission fluid level indicator from filler tube. 2. Place funnel in filler tube. 3. Raise vehicle on a hoist and place suitable safety stands under vehicle. 4. Remove cooler return line (rear fitting) from fitting on transmission case 5. Connect one end of a hose to cooler return line and route other end of hose up to a point where it can be inserted into funnel at filler tube. 6. Remove safety stands and lower vehicle. Insert end of hose into funnel. 7. Start engine and run at idle with transmission in NEUTRAL position. 8. When fluid flowing from hose is solid a liberal amount of fluid should be observed. "Liberal" is described as about .47L (1/2 quart) delivered in 30 seconds. If liberal flow is observed test is completed. 9. If flow is not liberal stop engine. Disconnect hose from cooler return line and connect it to converter outline fitting (front fitting) on transmission case 10. Repeat steps 7 and 8. If flow is now liberal refer to appropriate section for diagnosis of transmission fluid cooler. If flow is not liberal service pump or converter assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3867 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3868 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Testing and Inspection Vacuum Diaphragm: Testing and Inspection OFF VEHICLE TEST 1. Remove unit from transmission and, using suitable vacuum tester, adjust tester until vacuum gauge reads 18 inches with end of vacuum hose blocked off. 2. Connect vacuum hose to manifold vacuum port. 3. If gauge still reads 18 inches, vacuum unit diaphragm is not leaking. 4. A second leakage check can be made as the hose is removed from the transmission vacuum unit. 5. Hold a finger over the end of the vacuum control rod. 6. When the hose is removed the internal spring of the vacuum unit should push the control rod outward. 7. If the vacuum diaphragm needs replacing, install a new unit that has been released for service. ON VEHICLE TEST 1. Start the vacuum pump and set the regulator knob so that the vacuum gauge reads 18 inches with the end of the vacuum hose blocked off, then connect the vacuum hose to the diaphragm unit. 2. If the gauge still reads 18 inches, the vacuum diaphragm unit is not leaking. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Testing and Inspection > Page 3875 Vacuum Diaphragm: Service and Repair Vacuum Diaphragm Assembly Note: This procedure was taken from the Disassembly and Assembly articles of the A4LD Automatic Transmission. For additional information to access this assembly refer to the Disassembly and Assembly procedures. See: Service and Repair Removal Use a 10mm socket to remove one (M6 x 12mm) screw and retainer. Remove the vacuum diaphragm assembly and throttle valve actuator rod. Verify that the throttle valve moves freely using flat external snap ring pliers. Then remove the valve with the pliers. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Vacuum Diaphragm, A/T > Component Information > Testing and Inspection > Page 3876 NOTE: All 4 x 4 and 4.0L applications will use a studded bolt (M6 x 1.0). Tighten stud to 12-16 N-m (106-142 in-lb), screw to 9-12 N-m (80-106 in-lb). CAUTION: Make sure the valve moves freely in the bore. Install throttle valve, actuating rod, vacuum diaphragm and retaining clamp. Hold in position by tightening M6 x 12mm screw with a 10mm wrench. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation Valve Body: Description and Operation VALVE BODY CONTROL FUNCTIONS Valve Body Main Control Component Identification NOTE: The numbers in parenthesis correspond with the numbers in the Valve Body Main Control Component Identification image. (1) The intermediate servo accumulator controls band capacity on 1-2 shift. (2) The overdrive servo accumulator controls overdrive band capacity on 3-4 upshifts. (3) The 3-4 back-out valve controls the rate at which overdrive servo release oil exhausts on 3-4 back-out shifts. (4) The 3-2 high clutch release valve controls the rate at which high clutch oil exhausts on higher speed 3-2 downshifts. (5) The 3-2 intermediate servo release valve controls the rate at which intermediate servo release oil exhausts on higher speed 3-2 downshifts. (6) The 3-2 kickdown timing valve sends intermediate servo release and high clutch oil to the torque demand valve during 3-2 downshifts at lower speeds. At higher speed, this valve moves down and intermediate servo release and high clutch oil drains through the 3-2 intermediate servo release kickdown control and 3-2 high clutch kickdown control valves. (7) The 3-2 coast control valve controls the rate at which intermediate servo release and high clutch oil exhaust on 3-2 coasting downshifts. (8) The throttle pressure booster valve increases throttle pressure output for shift delay at lower engine manifold vacuum levels. (9) The 1-2 transition valve, along with the 2-3 back-out valve, will prevent an intermediate to reverse band tie-up on a manual 1-2 shift. (10) The 2-3 back-out valve prevents tie-up if driver backs off accelerator during 2-3 upshift. (11) The engagement control valve feeds the forward clutch through a small orifice at low Throttle Valve (TV) pressures, or through a larger orifice at higher TV pressures. (12) The torque demand control valve controls the rate at which high clutch and intermediate servo release oil exhausts at lower speed 3-2 downshifts. (13) The cut back valve reduces control pressure as road speed increases. (14) The oil pressure regulator valve regulates main control pressure. (15) The main oil pressure booster valve increases or decreases main control pressure in relation to throttle pressure, and provides higher line pressure in reverse. (16) The throttle downshift valve reroutes line pressure to override the normal automatic upshift schedule and provide forced downshifts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > Page 3880 (17) The manual control valve moves with shift selector and directs control pressure to various passages to provide automatic function. (18) The 2-Low range coasting boost valve boosts pressure in selector positions 1 and 2 at closed or nearly closed throttle. (19) The 1-2 shift valve controls upshift from 1st to second and downshift from 2nd to 1st. (20) The D2 shift valve is used in combination with the 1-2 shift valve to provide a 2nd gear start in 2 range. (21) The 2-3 shift valve controls upshift from 2nd to high and downshift from high to 2nd. (22) The 2-3 throttle pressure modulator valve provides a modulated pressure to the 2-3 shift valve at higher TV pressures. This modulated pressure helps to delay 2-3 shifts at higher TV pressures. (23) The 4-3 torque demand valve routes high clutch oil to the 3-4 shift valve at lower vacuums. This provides for a higher road speed 4-3 torque demands at lower vacuum. (24) The converter clutch shift valve, along with the converter clutch shuttle valve and solenoid, controls converter clutch engagements and disengagements. (25) The converter clutch throttle pressure modulator valve sends a modulated pressure to the converter clutch shift valve at higher TV pressures. This modulated pressure helps to delay converter clutch upshifts at higher TV pressures. (26) The 3-4 shift valve controls the scheduling for 3-4 upshifts and 4-3 downshifts. (27) The 3-4 throttle pressure modulator valve provides a modulated pressure on the 3-4 shift valve at high TV pressures. This modulated pressure helps to delay 3-4 upshifts at higher TV pressures. (28) The converter clutch shuttle valve, when bottomed against the plug, directs flow so the converter clutch will be disengaged. When the valve compresses the spring, flow is directed so the converter clutch engages. The solenoid also controls the position of this valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly Valve Body: Service and Repair Disassembly and Assembly Main Control Valve Body Disassembly 1. Remove three Torx head screws retaining valve body separating plate and control valve body to case gasket to valve body. 2. Remove the valve body separating plate. This plate is not serviced separately. Valve Body, Gasket, Separator Plate 3. Remove the main control to case gasket and separator to main control gasket. Replace with new main control to case gasket and separator to main control gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3883 Bore Location, Main Control Valve Body (Part 1 Of 2) Bore Location, Main Control Valve Body (Part 2 Of 2) 4. Clean and inspect valve body. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3884 Bore 200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3885 Bore 201 Bore 202 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3886 Bore 203 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3887 Bore 204 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3888 Bore 205 Bore 206 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3889 Bore 207 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3890 Bore 208 Bore 209 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3891 Bore 210 Bore 211 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3892 Bore 212 Bore 213 NOTE: Throttle Valve boost valve and spring are calibration dependent. With longer valve (approximately .015 inch), spring is omitted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3893 Bore 214 Bore 215 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3894 Bore 216 Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3895 Main Control Valve Body 1. CAUTION: Make sure all holes in gasket line up with holes in separator plate. Make sure all check balls, retainers, springs and valves are installed properly. 2. NOTE: Petroleum jelly can be used to hold gasket in place. Install a new valve body-to-separator plate gasket. 3. Install the separator plate using two tapered punches at locations "E" to align gasket and separator plate-to-valve body. Install three Torx head screws to retain separator plate and gasket to valve body. Tighten screw to 6-8 Nm (53-71 lb-in). 4. Remove alignment punches. 5. NOTE: Use petroleum jelly to hold the gasket in place. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Disassembly and Assembly > Page 3896 Install and align (upper) separator plate to case gasket. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair REMOVAL 1. Disconnect battery ground cable, then the clutch master cylinder from clutch pedal. 2. Raise and support vehicle, then remove starter. 3. Disconnect hydraulic coupling at transmission with coupling disconnect tool No. T88T-70522-A or equivalent by sliding white plastic sleeve toward slave cylinder and tugging on tube. 4. Remove transmission. If original components are to be reinstalled scribe pressure plate/cover and fly wheel for assembly reference. Exploded View Of Clutch Assembly 5. Loosen pressure plate and cover attaching bolts evenly until pressure plate springs are completely expanded, then remove bolts. 6. Remove pressure plate, cover assembly, and clutch disc from flywheel. Remove pilot bearing, if required. INSTALLATION 1. Reverse procedure to install, noting the following: a. Before tightening pressure plate bolts, insert clutch alignment tool No. T74P-7137-k or equivalent into clutch pilot bearing hole. Ensure clutch disc is properly aligned on flywheel. Pressure Plate Tightening Sequence Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 3901 b. Torque pressure plate bolts in sequence to 15-24 ft lbs. c. When battery has been disconnected and then reconnected, abnormal drive symptoms may be noted for 10 or more miles due to Powertrain Control Module (PCM) reset. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips Clutch Master Cylinder: Technical Service Bulletins Hydraulic Clutch - Bleeding Procedure Service Tips Article No. 93-12-19 06/09/93 ^ CLUTCH - "SOFT" UNRESPONSIVE CLUTCH PEDAL - AIR ENTRAPPED IN HYDRAULIC SYSTEM - SERVICE TIPS ^ CLUTCH - HYDRAULIC - UNABLE TO RELEASE - AIR ENTRAPPED IN SYSTEM - SERVICE TIPS ^ CLUTCH - HYDRAULIC BLEED PROCEDURE - SERVICE TIPS ^ TRANSMISSION - M50D AND ZF LIGHT DUTY - GEAR CLASH - AIR ENTRAPPED IN CLUTCH HYDRAULIC SYSTEM - SERVICE TIPS LIGHT TRUCK: 1993 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER ISSUE: A "soft" unresponsive clutch pedal may be felt or the driver may be unable to release the clutch. This is caused by air entrapped in the clutch hydraulic system. ACTION: Use the information in this TSB article in addition to the bleed procedure specified in the 1993 Service Manual. This article includes detail as well as extra service tips for easier hydraulic clutch bleeding. The clutch hydraulic system for the 1993 model year is new and more difficult to bleed than the previous hydraulic system. Therefore, a different bleeding procedure is required for these vehicles. RANGER, EXPLORER, AEROSTAR The most difficult systems to bleed are on the Rangers, Explorers and Aerostars. Follow the bleed procedure as outlined in the 1993 Service Manual, Page 08-00-6. This procedure with the addition of the bench bleed process is included in this TSB article. NOTE: WHEN INSTALLING DRY CLUTCH CYLINDER OR TUBE SERVICE PARTS, DO THE BENCH BLEED PROCEDURE FIRST. BENCH BLEED Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3907 The compact vehicles are more difficult to bleed because the downward angle of the master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed) air can escape much more efficiently. Refer to Figure 1. BENCH BLEEDING PROCEDURE (CONCENTRIC SLAVE CYLINDER) 1. Remove master cylinder, line and reservoir from vehicle and assemble with replacement parts required based on initial concern. 2. Hold the master cylinder vertically with the reservoir feed hose in the highest position on the body, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3908 3. Fill the reservoir and extend above the master cylinder and assure the quick connect on the clutch line is below the master cylinder. (Lightly clamp reservoir in a vice). 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve, Figure 1. 5. Stroke and hold master cylinder pushrod. 6. Close quick connect valve. 7. Release master cylinder pushrod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, proceed as follows: a. Push the pushrod into the body several times quickly to expel any remaining air. b. If it is a remote reservoir, pinch the supply hose with your fingers two or three times to help move air into reservoir. 11. When the movement of the pushrod is .160" (4 mm) or less when stroked in Step 10, reinstall the master cylinder into the vehicle and couple it to the slave cylinder. ON VEHICLE BLEED PROCEDURE, CONCENTRIC SLAVE CYLINDER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3909 Under normal conditions, disconnecting the clutch coupling will not introduce air into the system. However, if there appears to be air in the system (spongy pedal or insufficient bearing travel), the system must be bled. See Figure 2. The following procedure is used with the hydraulic system installed on the vehicle. 1. Disconnect the coupling at the transmission with a coupling disconnect tool (T88T70522A) or equivalent by sliding the white plastic sleeve toward the slave cylinder while applying a slight tug on the clutch tube. 2. Clean dirt and grease from around the reservoir cap. 3. Remove cap and diaphragm and fill reservoir to the step with Heavy Duty Brake Fluid (C6AZ-19542-AA or BA) (ESA-M6C25-A) or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3910 CAUTION: BRAKE FLUID MUST BE CERTIFIED TO DOT 3 SPECIFICATION. a. By hand, apply 10-15 lbs. to clutch pedal. b. If pedal is hard (.25-.50" movement), skip to Step 9. c. If pedal is spongy, proceed to the next step. 4. Using a small screwdriver.... a. Depress the internal mechanism of the male coupling to open the valve. b. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold. 5. Remove the screwdriver from the coupling, closing the valve. 6. Release the clutch pedal. 7. Refill the reservoir to level at step. NOTE: THE RESERVOIR MUST BE KEPT FULL AT ALL TIMES TO ENSURE THAT THERE WILL BE NO ADDITIONAL INTRODUCTION OF AIR INTO THE SYSTEM. 8. Repeat Steps 4 through 7. 9. Install cap on reservoir. a. Reconnect the coupling to the slave cylinder. b. Check that the connection is secure by applying a slight tug to the clutch tube. 10. Stroke the clutch pedal as rapidly as possible for five to ten strokes. 11. Wait one to three minutes. 12. Repeat Steps 10 and 11 three more times. 13. Loosen the bleed screw which is located in the slave cylinder body next to the inlet connection. 14. Depress and hold the clutch pedal while tightening the bleed screw 3-5 N-m (2.2-3.7 lb.ft.). 15. Refill the reservoir to level at step. 16. The hydraulic system should now be fully bled and should release the clutch. Check the clutch reserve per the instruction in the 1993 Service Manual, Section 08-00. F-SERIES, BRONCO Since full size vehicles have master cylinders which are mounted in a level attitude, they bleed more efficiently than do compact vehicles. However, some difficulties may still be encountered if the new procedure is not used. VEHICLES WITH CONCENTRIC SLAVE CYLINDERS The procedure given in the Service Manual on page 08-00-9 is incorrect. Use the same bleed procedure as specified for the compact vehicles which is included in this article. The optional bench bleed procedure may be used, but is probably not necessary. VEHICLES WITH EXTERNAL SLAVE CYLINDERS The procedure in the 1993 Service Manual on page 08-00-10 should be modified as follows: 1. Do not use the Alternate Method. 2. After Step 7 and before Step 8, do the following... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Technical Service Bulletins > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3911 a. Remove the slave cylinder from the transmission. b. Holding the cylinder so that the port for the tube is at the highest point, slowly push the pushrod into the cylinder and slowly let it return. Be sure the reservoir is full of fluid beforehand. Repeat this step two more times. c. Reattach the slave cylinder to the transmission. d. Rapidly depress the clutch pedal 10 times through a travel of about 1" (25.4 mm). e. If the pedal is not hard within .25" (6.35 mm) to .5" (12.7 mm) of travel, repeat Step d. PART NUMBER PART NUMBER CLASS C6AZ-19542-AA Heavy Duty Brake B OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper warranty Coverage OPERATION DESCRIPTION TIME 931219A On Vehicle Bleed 0.8 Hr. Procedure - Concentric Slave Cylinder Equipped Vehicles 931219B Master Cylinder Bench 1.1 Hrs. Bleed Procedure - Concentric Slave Cylinder Equipped Vehicles 931219C On-Vehicle Bleed Procedure 0.6 Hr. - External Slave Equipped Vehicles DEALER CODING BASIC PART NO. CONDITION CODE 7A543 07 OASIS CODES: 505000, 505200, 506000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleed Procedure Clutch Master Cylinder: Service and Repair Bleed Procedure NOTE: Under normal conditions, disconnecting the clutch coupling will not introduce air into the system. However, if there appears to be air in the system, (spongy pedal, or insufficient bearing travel) the system must be bled. The largest portion of bleeding is carried out by gravity. REMOVAL AND INSTALLATION 1. Disconnect coupling at transmission with Clutch Coupling tool No. T88T-70522-A or equivalent by sliding white plastic sleeve toward clutch slave cylinder while applying a slight tug on clutch tube. 2. Clean dirt and grease from around the reservoir cap. 3. Remove cap and diaphragm, then fill reservoir to step with Heavy Duty Brake Fluid part No. C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent. Brake fluid must be certified DOT 3 or 4 specification. 4. Using a screwdriver, depress internal mechanism of male coupling to open valve. While continuing to hold valve open, slowly depress and hold clutch pedal to floor. 5. Remove screwdriver from coupling, closing valve. Release clutch pedal. 6. Refill reservoir to level at step, then repeat Steps 4 and 5. 7. Close reservoir. Reconnect coupling to clutch slave cylinder. Check that connection is secure by applying a slight tug to clutch tube. 8. Stroke clutch pedal as rapidly as possible 5 to 10 times, wait one to three minutes, then repeat three more times. 9. Loosen bleed screw (located in clutch slave cylinder next to inlet connection), then depress and hold clutch pedal while tightening bleed screw. 10. Refill clutch master cylinder reservoir to level at step. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleed Procedure > Page 3914 Clutch Master Cylinder: Service and Repair Clutch Master Cylinder Bench Bleeding Clutch Master Cylinder The downward angle of the clutch master cylinder (7A543) makes it difficult for air to escape up into the reservoir. Therefore, if the clutch master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed), air can escape much more efficiently. 1. Start with tube and reservoir attached to clutch master cylinder, but system removed from vehicle. Lightly clamp reservoir is a vise. 2. Hold the clutch master cylinder vertically with reservoir feed hose in the highest position on the body. 3. Fill reservoir and extend above clutch master cylinder and make sure the quick connect on clutch line is below the clutch master cylinder. 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve. 5. Stroke and hold master cylinder push rod. 6. Close quick connect valve. 7. Release master cylinder push rod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the clutch master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, push the push rod into the body several times quickly to expel any remaining air (if remote reservoir, pinch supply hose with fingers two or three times to help move air into reservoir). 11. When the movement of the push rod is 4mm (.160 inch) or less when stroked in Step 10 above, the clutch master cylinder may be reinstalled into the vehicle and coupled to the concentric clutch slave cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Bleed Procedure > Page 3915 Clutch Master Cylinder: Service and Repair Removal and Installation Clutch Master Cylinder Replacement Removal 1. Disconnect clutch master cylinder push rod from clutch pedal by prying retainer bushing and push rod off pedal pin. 2. Disconnect clutch pedal position switch from master cylinder assembly. 3. Remove clutch master cylinder reservoir screw from the inner fender panel. 4. Uncouple the line from clutch slave cylinder. Disconnect tube from slave cylinder using tool No. T88T-70522A or equivalent by sliding white plastic sleeve toward slave cylinder and tugging on tube. Remove tube from mounting clips. 5. wist the clutch master cylinder 1/8 turn counterclockwise as viewed from the driver's position, while pushing inward toward the driver's position. The rubber dash boot is removed with the master cylinder. Installation 1. Bench bleed the clutch master cylinder. 2. install the push rod through the hole in the engine compartment. Be sure it is located on the correct side of the clutch pedal. 3. Place the clutch master cylinder in position and rotate the body 1/8 turn clockwise as viewed from the driver's position while pushing inward. Install the dash seal into the dash hole and check that it is completely inserted into the hole. 4. Position the clutch master cylinder reservoir on the cowl access cover and install the retaining screws. 5. Replace clutch master cylinder push rod retainer bushing if worn or damaged. 6. Install the clutch pedal position switch. 7. Install the retainer and push rod on the clutch pedal pin with the flange portion of the bushing facing away from the pedal blade of the clutch pedal. 8. Bleed the system. 9. Insert the coupling end into the clutch slave cylinder, and install line into clip(s). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 97-22-17 > Oct > 97 > Clutch - Hard to Depress/Premature Slave Cylinder Wear Clutch Slave Cylinder: Customer Interest Clutch - Hard to Depress/Premature Slave Cylinder Wear Article No. 97-22-17 10/27/97 CLUTCH - HARD TO DISENGAGE OR FREQUENT REPLACEMENT OF CLUTCH SLAVE CYLINDER - EARLY WEAR-OUT OF SLAVE CYLINDER LIGHT TRUCK: 1993-96 BRONCO 1993-97 EXPLORER, F-150-350 SERIES, RANGER ISSUE: The clutch may be hard to depress and/or the clutch slave cylinder may wear out prematurely on some vehicles. This may be due to the clutch slave cylinder allowing hydraulic fluid to leak by the internal seal. ACTION: Replace the clutch slave cylinder. The revised slave cylinder has a new dust shield and upgraded lip seal to help prevent leakage of hydraulic fluid in the slave cylinder. Refer to the appropriate model/year Service Manual, Section 08-00 for clutch system diagnostics, and Section 08-02 for removal and installation details. PART NUMBER PART NAME F87Z-7A508-AA Clutch Slave Cylinder OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972217A Replace Clutch Slave 0.3 Hr. Cylinder (to be used along with 7003A) DEALER CODING CONDITION BASIC PART NO. CODE 7A508 49 OASIS CODES: 505000, 505200, 506000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 97-22-17 > Oct > 97 > Clutch Hard to Depress/Premature Slave Cylinder Wear Clutch Slave Cylinder: All Technical Service Bulletins Clutch - Hard to Depress/Premature Slave Cylinder Wear Article No. 97-22-17 10/27/97 CLUTCH - HARD TO DISENGAGE OR FREQUENT REPLACEMENT OF CLUTCH SLAVE CYLINDER - EARLY WEAR-OUT OF SLAVE CYLINDER LIGHT TRUCK: 1993-96 BRONCO 1993-97 EXPLORER, F-150-350 SERIES, RANGER ISSUE: The clutch may be hard to depress and/or the clutch slave cylinder may wear out prematurely on some vehicles. This may be due to the clutch slave cylinder allowing hydraulic fluid to leak by the internal seal. ACTION: Replace the clutch slave cylinder. The revised slave cylinder has a new dust shield and upgraded lip seal to help prevent leakage of hydraulic fluid in the slave cylinder. Refer to the appropriate model/year Service Manual, Section 08-00 for clutch system diagnostics, and Section 08-02 for removal and installation details. PART NUMBER PART NAME F87Z-7A508-AA Clutch Slave Cylinder OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 972217A Replace Clutch Slave 0.3 Hr. Cylinder (to be used along with 7003A) DEALER CODING CONDITION BASIC PART NO. CODE 7A508 49 OASIS CODES: 505000, 505200, 506000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips Clutch Slave Cylinder: All Technical Service Bulletins Hydraulic Clutch - Bleeding Procedure Service Tips Article No. 93-12-19 06/09/93 ^ CLUTCH - "SOFT" UNRESPONSIVE CLUTCH PEDAL - AIR ENTRAPPED IN HYDRAULIC SYSTEM - SERVICE TIPS ^ CLUTCH - HYDRAULIC - UNABLE TO RELEASE - AIR ENTRAPPED IN SYSTEM - SERVICE TIPS ^ CLUTCH - HYDRAULIC BLEED PROCEDURE - SERVICE TIPS ^ TRANSMISSION - M50D AND ZF LIGHT DUTY - GEAR CLASH - AIR ENTRAPPED IN CLUTCH HYDRAULIC SYSTEM - SERVICE TIPS LIGHT TRUCK: 1993 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER ISSUE: A "soft" unresponsive clutch pedal may be felt or the driver may be unable to release the clutch. This is caused by air entrapped in the clutch hydraulic system. ACTION: Use the information in this TSB article in addition to the bleed procedure specified in the 1993 Service Manual. This article includes detail as well as extra service tips for easier hydraulic clutch bleeding. The clutch hydraulic system for the 1993 model year is new and more difficult to bleed than the previous hydraulic system. Therefore, a different bleeding procedure is required for these vehicles. RANGER, EXPLORER, AEROSTAR The most difficult systems to bleed are on the Rangers, Explorers and Aerostars. Follow the bleed procedure as outlined in the 1993 Service Manual, Page 08-00-6. This procedure with the addition of the bench bleed process is included in this TSB article. NOTE: WHEN INSTALLING DRY CLUTCH CYLINDER OR TUBE SERVICE PARTS, DO THE BENCH BLEED PROCEDURE FIRST. BENCH BLEED Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3933 The compact vehicles are more difficult to bleed because the downward angle of the master cylinder makes it difficult for air to escape up into the reservoir. Therefore, if the master cylinder is removed from the vehicle and bled while held in a vertical orientation (a bench bleed) air can escape much more efficiently. Refer to Figure 1. BENCH BLEEDING PROCEDURE (CONCENTRIC SLAVE CYLINDER) 1. Remove master cylinder, line and reservoir from vehicle and assemble with replacement parts required based on initial concern. 2. Hold the master cylinder vertically with the reservoir feed hose in the highest position on the body, Figure 1. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3934 3. Fill the reservoir and extend above the master cylinder and assure the quick connect on the clutch line is below the master cylinder. (Lightly clamp reservoir in a vice). 4. Using a small screwdriver, depress the internal mechanism of the male quick connect coupling to open the valve, Figure 1. 5. Stroke and hold master cylinder pushrod. 6. Close quick connect valve. 7. Release master cylinder pushrod. 8. Fill reservoir. 9. Repeat Steps 4 through 8 four more times. 10. With the master cylinder still being held with the outlet tube and reservoir feed tube ends high, quick connect closed and the reservoir full, proceed as follows: a. Push the pushrod into the body several times quickly to expel any remaining air. b. If it is a remote reservoir, pinch the supply hose with your fingers two or three times to help move air into reservoir. 11. When the movement of the pushrod is .160" (4 mm) or less when stroked in Step 10, reinstall the master cylinder into the vehicle and couple it to the slave cylinder. ON VEHICLE BLEED PROCEDURE, CONCENTRIC SLAVE CYLINDER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3935 Under normal conditions, disconnecting the clutch coupling will not introduce air into the system. However, if there appears to be air in the system (spongy pedal or insufficient bearing travel), the system must be bled. See Figure 2. The following procedure is used with the hydraulic system installed on the vehicle. 1. Disconnect the coupling at the transmission with a coupling disconnect tool (T88T70522A) or equivalent by sliding the white plastic sleeve toward the slave cylinder while applying a slight tug on the clutch tube. 2. Clean dirt and grease from around the reservoir cap. 3. Remove cap and diaphragm and fill reservoir to the step with Heavy Duty Brake Fluid (C6AZ-19542-AA or BA) (ESA-M6C25-A) or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3936 CAUTION: BRAKE FLUID MUST BE CERTIFIED TO DOT 3 SPECIFICATION. a. By hand, apply 10-15 lbs. to clutch pedal. b. If pedal is hard (.25-.50" movement), skip to Step 9. c. If pedal is spongy, proceed to the next step. 4. Using a small screwdriver.... a. Depress the internal mechanism of the male coupling to open the valve. b. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold. 5. Remove the screwdriver from the coupling, closing the valve. 6. Release the clutch pedal. 7. Refill the reservoir to level at step. NOTE: THE RESERVOIR MUST BE KEPT FULL AT ALL TIMES TO ENSURE THAT THERE WILL BE NO ADDITIONAL INTRODUCTION OF AIR INTO THE SYSTEM. 8. Repeat Steps 4 through 7. 9. Install cap on reservoir. a. Reconnect the coupling to the slave cylinder. b. Check that the connection is secure by applying a slight tug to the clutch tube. 10. Stroke the clutch pedal as rapidly as possible for five to ten strokes. 11. Wait one to three minutes. 12. Repeat Steps 10 and 11 three more times. 13. Loosen the bleed screw which is located in the slave cylinder body next to the inlet connection. 14. Depress and hold the clutch pedal while tightening the bleed screw 3-5 N-m (2.2-3.7 lb.ft.). 15. Refill the reservoir to level at step. 16. The hydraulic system should now be fully bled and should release the clutch. Check the clutch reserve per the instruction in the 1993 Service Manual, Section 08-00. F-SERIES, BRONCO Since full size vehicles have master cylinders which are mounted in a level attitude, they bleed more efficiently than do compact vehicles. However, some difficulties may still be encountered if the new procedure is not used. VEHICLES WITH CONCENTRIC SLAVE CYLINDERS The procedure given in the Service Manual on page 08-00-9 is incorrect. Use the same bleed procedure as specified for the compact vehicles which is included in this article. The optional bench bleed procedure may be used, but is probably not necessary. VEHICLES WITH EXTERNAL SLAVE CYLINDERS The procedure in the 1993 Service Manual on page 08-00-10 should be modified as follows: 1. Do not use the Alternate Method. 2. After Step 7 and before Step 8, do the following... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 931219 > Jun > 93 > Hydraulic Clutch - Bleeding Procedure Service Tips > Page 3937 a. Remove the slave cylinder from the transmission. b. Holding the cylinder so that the port for the tube is at the highest point, slowly push the pushrod into the cylinder and slowly let it return. Be sure the reservoir is full of fluid beforehand. Repeat this step two more times. c. Reattach the slave cylinder to the transmission. d. Rapidly depress the clutch pedal 10 times through a travel of about 1" (25.4 mm). e. If the pedal is not hard within .25" (6.35 mm) to .5" (12.7 mm) of travel, repeat Step d. PART NUMBER PART NUMBER CLASS C6AZ-19542-AA Heavy Duty Brake B OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper warranty Coverage OPERATION DESCRIPTION TIME 931219A On Vehicle Bleed 0.8 Hr. Procedure - Concentric Slave Cylinder Equipped Vehicles 931219B Master Cylinder Bench 1.1 Hrs. Bleed Procedure - Concentric Slave Cylinder Equipped Vehicles 931219C On-Vehicle Bleed Procedure 0.6 Hr. - External Slave Equipped Vehicles DEALER CODING BASIC PART NO. CONDITION CODE 7A543 07 OASIS CODES: 505000, 505200, 506000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch Slave Cylinder: > 951514 > Jul > 95 > A/C System - Lack of Cooling Expansion Block/Orifice Tube: All Technical Service Bulletins A/C System - Lack of Cooling Article No. 95-15-14 07/31/95 ^ AIR CONDITIONING - LACK OF COOLING - ORIFICE TUBE BLOCKING EVAPORATOR CORE - VEHICLES BUILT FROM 10/1/94 THROUGH 12/31/94 ^ AIR CONDITIONING - ORIFICE TUBE MISSING/OUT OF POSITION - VEHICLES BUILT 10/1/94 THROUGH 12/31/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A lack of A/C cooling may be observed on some vehicles. This may be due to an incorrect crimp on the evaporator inlet tube which retains the orifice tube in the proper position. This may allow the orifice tube to slip and lodge in the evaporator core. This condition may cause a restriction or appear that the orifice tube is missing, resulting in lack of cooling. ACTION: Replace the evaporator core and orifice tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the concern using the procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. 2. If the pressure cycling time test indicates a missing orifice tube or an evaporator restriction, recover the refrigerant using an approved refrigerant recovery system. 3. Disconnect the evaporator inlet tube and look for the orifice lodged inside the evaporator core. 4. If the orifice tube is lodged inside the evaporator core, replace the evaporator core and orifice tube. If the orifice tube is not lodged in the evaporator core, refer to Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual for diagnostic procedures. 5. Evacuate and recharge the A/C system according to procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. PART NUMBER PART NAME E3TZ-19860-C Evaporator core F3XY-19D990-A Orifice Tube OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951514A Replace A/C Evaporator 2.2 Hrs. Core And Orifice Tube DEALER CODING CONDITION BASIC PART NO. CODE 19860 55 OASIS CODES: 208200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Procedure Clutch Slave Cylinder: Service and Repair Bleeding Procedure NOTE: On vehicles equipped with quick-connect clutch tube, the manufacturer recommends replacing the tube when ever hydraulic system service is necessary, because the quick-connect feature tends to trap air in the system and prevents complete bleeding of the system. The replacement tube does not include the quick-connect feature. 1. Clean area around fluid reservoir cap, then remove cap and fill reservoir with suitable DOT 3 brake fluid. 2. Loosen bleed screw on slave cylinder and wait until a steady stream of fluid is expelled, then tighten screw. 3. Depress clutch pedal to floor, wait 1-2 seconds, then release pedal as rapidly as possible. Repeat approximately 10 times. 4. Check fluid level in reservoir and fill as required. 5. Repeat steps 3 and 4, then reinstall reservoir cap. 6. Hold clutch pedal to floor, crack open bleed screw to allow any additional air to escape, then close screw and release clutch pedal. Check fluid level and adjust as necessary. 7. Start engine, then depress clutch pedal and shift transmission into reverse gear. If gear clash occurs, repeat steps 3 through 6. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Procedure > Page 3950 Clutch Slave Cylinder: Service and Repair Clutch Slave Cylinder to Clutch Master Cylinder Tube Removal and Installation 1. Raise vehicle on a hoist and position suitable safety stands under vehicle. 2. Disconnect the line from the plastic clip at the floor flange. Clutch Coupling Tool T88T-70522-A 3. Uncouple the lower end of the line from the clutch slave cylinder using Clutch Coupling Tool T88T-70522-A by sliding the white plastic sleeve toward the clutch slave cylinder while pulling the line away from the clutch slave cylinder. 4. Remove the safety stands and lower the vehicle. 5. Remove and discard the roll pin holding the line to the clutch master cylinder. 6. Disconnect the line from the clutch master cylinder by applying a slight tug on the line pulling away from the clutch master cylinder. 7. Check to be sure the O-ring is still in the outlet port of the clutch master cylinder. lf not, replace. 8. Insert the new line into the clutch master cylinder outlet port. 9. Install a new roll pin to secure the line in place at the clutch master cylinder. Check installation by pulling the line away from the clutch master cylinder outlet port. 10. Bleed the system. See: Service and Repair/Clutch System Bleed 11. If a new line is installed, remove the yellow rubber protective cap and check that the O-ring is in place. Check the master cylinder port to be sure there is no O-ring in the master cylinder before installing the new line. Insert the male coupling end into the female coupling of the clutch slave cylinder (7A508). NOTE: Once the line is attached to the clutch slave cylinder, check that the connection is secure by applying a slight tug to the clutch tube. 12. Connect the line to the plastic clip at the floor flange. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Bleeding Procedure > Page 3951 Clutch Slave Cylinder: Service and Repair Removal and Installation Slave Cylinder Removal REMOVAL Clutch Coupling Tool T88T-70522-A 1. Using coupling disconnect tool No. T88T-70522-A or equivalent, disconnect hydraulic coupling at transmission by sliding white plastic sleeve toward clutch slave cylinder while tugging on tube. 2. Remove transmission. 3. Remove clutch housing to transmission attaching bolts, then separate clutch housing from transmission. 4. Remove slave cylinder from transmission input shaft. INSTALLATION 1. Reverse procedure to install, noting the following: a. Position slave cylinder over transmission input shaft with bleed screw and coupling facing left side of transmission. b. Torque slave cylinder retaining bolts to 14-19 ft lbs. c. Bleed system if required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Tools and Equipment Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Linkage > Component Information > Adjustments Clutch Linkage: Adjustments The hydraulic clutch system provides automatic clutch adjustment for disc wear. The clutch actuation system does not have free play. It is automatically self-adjusting and will not require any routine service throughout the life of the clutch. No adjustment of clutch linkage or clutch pedal position is required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments Clutch Pedal Assembly: Adjustments The hydraulic clutch system provides automatic clutch adjustment for disc wear. The clutch actuation system does not have free play. It is automatically self-adjusting and will not require any routine service throughout the life of the clutch. No adjustment of clutch linkage or clutch pedal position is required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 3964 Clutch Pedal Position Switch: Description and Operation OPERATION The Powertrain Control Module (PCM) sends out a 5 volt reference to the Clutch Pedal Position (CPP) switch. When the switch is "OPEN" (clutch DEPRESSED), the PCM senses voltage. When the switch is "CLOSED" (clutch RELEASED), the PCM senses no voltage. The PCM uses this input to determine engine load and to adjust idle speed accordingly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 3965 Clutch Pedal Position Switch: Service and Repair Fig. 8 Clutch Interlock 3-way Switch REMOVAL 1. Disconnect electrical connector from switch located on clutch master cylinder push rod, Fig. 8. 2. Pull orientation clip away from switch to separate pin, then rotate switch to expose plastic retainer. 3. Push tabs together to allow retainer to slide rearward and separate from switch. 4. Remove switch from push rod. INSTALLATION 1. Install switch onto master cylinder push rod, ensuring that switch is properly seated. 2. Install plastic retainer, then rotate switch into position and attach orientation clip. 3. Connect electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection Carrier Bearings: Testing and Inspection Bearing Cups Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert 0.0015 inch feeler gauge between cups and bottoms of bores. Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Bearing Adjusters Test fit of bearing adjusters in their threads with bearing caps installed. Ensure bearing caps are on sides that they were machined to fit. The faces of the adjusters that contact the bearing cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace any adjuster with a damaged face or threads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection Differential Case: Testing and Inspection Ensure the hubs where bearings mount are smooth. Check fit of differential gears in the counterbores. Carefully examine thrust washers, which may be damaged when bearings are removed. If differential bearing assemblies do not seat firmly on hubs, failure is certain. Ensure mating surfaces of the two parts of case and the face of the ring gear attaching flange are smooth and free from nicks and burrs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Standard Type Differential Case: Service and Repair Standard Type 1. Remove pinion gears and thrust washers, rotating as necessary to align with windows. 2. Remove side gears and thrust washers. 3. Remove and discard ring gear attaching bolts, then press ring gear off of case. Models equipped with anti-lock brakes incorporate an exciter ring located on the ring gear. Removal of this ring is not necessary when removing ring gear, but care should be taken when removing ring gear assembly. 4. Using suitable puller, remove differential bearings from case. 5. Using suitable press, install differential bearings on case. 6. Install ring gear on case, coat bolts with suitable locking compound and tighten to 70-85 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Standard Type > Page 3976 Differential Case: Service and Repair Clutch Type, Traction-LOC Limited Slip DISASSEMBLE 1. Remove pinion shaft lock screw and pinion shaft. 2. Push axle shafts inward and remove C-clips from axle shafts. Remove axle shafts. Fig. 6 S-Shaped Preload Spring Removal 3. Remove preloaded "S" shaped spring. Use caution when removing "S" shaped spring since it is under tension. Fig. 7 Pinion Gear Replacement 4. Rotate pinion gears and thrust washers until they can be removed through access hole using 12 inch socket extension inserted into tool No. T80P-4205-A, or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Standard Type > Page 3977 Fig. 5 Exploded View Of Traction-Lok Differential 5. Remove left and right side gears, clutch packs and shims. Note order of removal for reference during assembly. INSPECTION 1. Visually inspect clutch packs, side gears, pinion gears and pinion shaft for damage or wear and replace as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Standard Type > Page 3978 Fig. 8 Clutch Pack Shim Thickness Measurement Tool Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Standard Type > Page 3979 Fig. 9 Shim Thickness Measurement 2. Place each clutch pack without shims into tool No. T80P-4946-A, or equivalent. Tighten nut to specifications. Using feeler gauge, determine thickness of new shims by inserting thickest blade possible between clutch pack and tool. ASSEMBLE 1. Apply suitable lubricant to clutch plates, then install left side gear, clutch pack and new shim into differential case. Repeat procedure for right hand side. 2. Install pinion gears and thrust washers 180° apart and in contact with side gears. Fig. 6 S-Shaped Preload Spring Removal 3. Align gears with pinion shaft bore, using 12 inch socket extension inserted in pinion shaft rotator. 4. Install "S" shaped preload spring into differential using soft faced hammer. 5. Install axle shafts and secure with C-clip. 6. Install pinion shaft. Apply Loctite(R) or equivalent onto pinion shaft lock bolt and tighten to 15-30 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 96129 > Jun > 96 > Differential Chatter On Turns Differential Clutch: Customer Interest Differential - Chatter On Turns Article No. 96-12-9 06/03/96 ^ NOISE - "CHATTER" DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR REAR AXLES ^ AXLE - NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR ^ AXLE - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR - "CHATTER" NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER 1989-97 F-150 1991-96 EXPLORER ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials. ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details. NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS. REAR AXLE ASSEMBLY IDENTIFICATION See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt. The Clutch Pack Replacement kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7145) The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 96129 > Jun > 96 > Differential Chatter On Turns > Page 3988 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 96129 > Jun > 96 > Differential - Chatter On Turns Differential Clutch: All Technical Service Bulletins Differential - Chatter On Turns Article No. 96-12-9 06/03/96 ^ NOISE - "CHATTER" DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR REAR AXLES ^ AXLE - NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR ^ AXLE - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR - "CHATTER" NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER 1989-97 F-150 1991-96 EXPLORER ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials. ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details. NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS. REAR AXLE ASSEMBLY IDENTIFICATION See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt. The Clutch Pack Replacement kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7145) The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 96129 > Jun > 96 > Differential - Chatter On Turns > Page 3994 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Specifications Differential Cover: Specifications Cover Bolts .......................................................................................................................................... ................................................................. 15-20 ft lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > External Structural Repair Differential Axle Housing: Service and Repair External Structural Repair Inspect visually for damage. Ensure differential bearing bores are smooth and that threads are not damaged. Remove any nicks or burrs from mounting surfaces of housing. Only repairs to cast axle housing and the "puddle-welded" area of the housing are approved. They should be made as follows: 1. Clean surfaces to be repaired by grinding or rotary filing to a clean bright metal finish. Clean repair area thoroughly. Metallic plastic will not stick to a dirty or oily surface. Chamfer or undercut the hole or porosity to a greater depth than the rest of the cleaned surface. Solid metal must surround the hole. Openings larger than 1/4 inch should not be repaired with metallic plastic. They can be drilled, tapped and plugged using common tools. 2. Mix metallic plastic base and hardener according to manufacturer's instructions. Stir thoroughly until uniform. 3. Apply repair mixture with suitable clean tool, forcing epoxy into hole or porosity. 4. Allow repair mixture to harden. Heat cure with a 250 watt lamp placed 10 inches from repaired surface, or air dry for 10 to 12 hours at temperatures above 50°F. 5. Sand or grind repaired area to blend with general contour of surrounding surface. 6. Paint the surface to match the rest of the axle housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > External Structural Repair > Page 4002 Differential Axle Housing: Service and Repair Rear Differential REMOVAL AND INSTALLATION 1. Raise vehicle and support at rear frame members. 2. Remove rear wheels and brake drums. 3. Drain rear axle lubricant by removing housing cover. 4. Remove axle shafts. 5. Remove 4 retaining nuts from each backing plate and wire the plates aside. 6. Disconnect rear axle housing vent. 7. Disconnect brake line from retaining clips on axle housing. 8. Remove hydraulic brake T-fitting from axle housing. 9. Mark driveshaft and axle flange for assembly reference, then disconnect shaft from flange. 10. Support axle with a suitable jack, then remove U-bolt nuts, U-bolts and plates. 11. Disconnect lower shock absorber studs from axle housing mounting brackets. 12. Lower axle housing and remove from vehicle. 13. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Differential Fluid Types And Capacities Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4007 Fluid - Differential: Fluid Type Specifications Key to Lubrication Abbreviations KEY TO LUBRICATION ABBREVIATIONS NOTE: Some manufacturer lubricant names may differ from the following list. If the manufacturer does not recommend a specific lubricant, use the following. AF Dexron(r)-III Automatic Transmission Fluid AP ATF-PLUS(r) Automatic Transmission Fluid BJ Suspension Lubricant BL Brake Lubricant CC Motor Oil, API Service CC CD Motor Oil, API Service CD CE Motor Oil, API Service CE CF-4 Motor Oil, API Service CF-4 DC Distributor Cam Lubricant EC Ethylene Glycol Coolant EP Extreme Pressure Gear Oil FA Automatic Transmission Fluid, Type F GC Wheel Bearing Grease, NLGI Classification GC GF-1 Motor Oil, API Service GF-1 (Starburst) GL-1 Gear Oil, API Service GL-1 GL-4 Gear Oil, API Service GL-4 GL-5 Gear Oil, API Service GL-5 GL-5* GL-5 Gear Oil for Limited Slip Differentials GLS Gear Lubricant, Special HB Hydraulic Brake Fluid, SAE J1703, DOT-3 or 4 HBH Hydraulic Brake Fluid, Extra Heavy Duty HG High Temperature Grease HP Hypoid Gear Oil HP* Hypoid Gear Oil for Limited Slip or Traction-Lok Differentials LB Chassis Grease, NLGI Classification LB LL Steering Linkage Lubricant LM Lithium Multipurpose Grease LS Steering Gear Lubricant MA Mercon(r) Automatic Transmission Fluid MH Manifold Heat Riser Solvent MO Motor Oil, Any API Service Classification PC Carburetor Cleaner PS Power Steering Fluid SF Motor Oil, API service SF SG Motor Oil, API service SG SH Motor Oil, API service SH SLF Special Lubricant - Fluid SLS Special Lubricant - Spray WB Wheel Bearing Grease Rear Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4008 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Measurement Specification Pinion Bearing: Specifications Measurement Specification PINION BEARING PRELOAD Adjustment Method .............................................................................................................................. ............................................... Collapsible Spacer New Bearings [1] .................................................. .............................................................................................................................. 16-29 Inch Pounds Used Bearings [1] ................................................................................................................................ .................................................. 8-14 Inch Pounds [1] Rotational torque. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Measurement Specification > Page 4013 Pinion Bearing: Specifications Torque Specification PINION NUT TO DRIVE PINION Pinion Shaft Nut [1] .............................................................................................................................. ............................................................... 217 ft lb [1] If pinion bearing preload exceeds specification before torque is obtained, replace collapsible spacer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Specifications > Page 4014 Pinion Bearing: Testing and Inspection Pinion Retainer Inspect visually for damage. Ensure pinion bearing cups are seated. Ensure there are no chips or burrs on mounting flange. Clean all lubricant passages. If pinion bearing cups were removed, examine bores in retainer carefully. Any nicks or burrs in these bores must be removed to permit proper seating of cups. Bearing Cups Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert 0.0015 inch feeler gauge between cups and bottoms of bores. Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Companion Flange Be sure that flat machined surfaces and the bearing cup sockets of the flange have not been damaged in removing driveshaft or in removing flange from axle. The edge of the flange that contacts the oil slinger or pinion front bearing must be smooth. Roughness aggravates backlash noises and causes wear on the slinger with a resultant loss in drive pinion bearing preload. The seal surface should be perfectly smooth or leakage will result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Measurement Specification Pinion Gear: Specifications Measurement Specification RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings (Preferred) [1] ................................................................................................................................................... 0.012 - 0.015 Inch New / Used Bearings (Minimum) [1] .................................................................................................................................................. 0.008 - 0.015 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Measurement Specification > Page 4019 Pinion Gear: Specifications Torque Specification PINION NUT TO DRIVE PINION Pinion Shaft Nut [1] .............................................................................................................................. ............................................................... 217 ft lb [1] If pinion bearing preload exceeds specification before torque is obtained, replace collapsible spacer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Specifications > Page 4020 Pinion Gear: Testing and Inspection Examine drive pinion teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Measurement Specification Ring Gear: Specifications Measurement Specification RING GEAR & PINION BACKLASH Adjustment Method .............................................................................................................................. ................................................................... Shims New / Used Bearings (Preferred) [1] ................................................................................................................................................... 0.012 - 0.015 Inch New / Used Bearings (Minimum) [1] .................................................................................................................................................. 0.008 - 0.015 Inch [1] Measurements taken at three different points cannot vary more than 0.003 inch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Measurement Specification > Page 4025 Ring Gear: Specifications Torque Specification RING GEAR TO DIFFERENTIAL CASE Ring Gear Bolts [1] .............................................................................................................................. ............................................................ 70-85 ft lb [1] Coat threads with Loctite(R) part number EOAZ-19554-B, or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Specifications > Page 4026 Ring Gear: Testing and Inspection CLEANING AND INSPECTION Examine ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. TESTING Models equipped with anti-lock brakes incorporate a multi-tooth exciter ring which is pressed on the differential case located behind the ring gear assembly. Do not remove exciter ring to measure ring gear runout. A space is provided between the exciter ring and ring gear to measure ring gear runout. NOTE: If ring gear runout during disassembly exceeded 0.008-0.015 inch, the condition may be caused by a warped gear, or distorted or damaged case or foreign matter trapped between differential case halves or under ring gears. To determine cause of excessive runout, assemble differential case without ring gear, then check as described below. 1. Install case in differential carrier without ring gear attached. 2. Install bearing caps and adjuster nuts and tighten cap bolts to 70-85 ft lb. 3. Tighten adjuster nuts to center differential side bearing. 4. Mount a dial indicator and check runout of case flange and ring gear pilot. If runout at either point is excessive, install a new differential case. If runout is within 0.012-0.015 inch, the ring gear is out of specification. NOTE: When performing this check on a locking differential case the four compression springs within the case should be temporarily removed. This will prevent a false runout reading due to distortion caused by the springs forcing the case apart. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > All Except 3.73:1 and 4.10:1 Axle Shaft: Service and Repair All Except 3.73:1 and 4.10:1 REMOVAL AND INSTALLATION 1. Raise and support vehicle. 2. Remove rear wheels and brake drums. 3. Drain rear axle lubricant by removing housing cover. 4. Remove axle shafts as follows: a. Remove differential pinion shaft lock bolt and the shaft. Fig. 4 Axle Shaft Removal b. Push axle shafts inward toward center of vehicle and remove C-lockwashers from shafts, Fig. 4. c. Carefully slide axle shafts out of housing. 5. Remove seal and bearing using a suitable hook-type puller. 6. Reverse procedure to install, noting the following: a. Apply suitable grease between lips of axle shaft seal. b. Install bearing using axle tube bearing replacer tool No. T78P-1225-A, and install seal and using axle tube seal replacer tool No. T78P-1177-A or equivalents. c. Tighten differential pinion shaft lock bolt to 15-30 ft lb Housing cover bolts to 25-35 ft lb Housing cover ratio tag bolt to 15-24 ft lb. NOTE: Whenever a plastic axle housing cover is removed, it must be replaced with a new cover and bolts. On plastic axle housing covers torque bolts to 15-20 ft lb. d. Add rear axle lubricant EOAZ-19580-AA or equivalent until it is 6-14 mm (1/4 - 9/16 inch) below the fill hole. Add 4oz. of friction modifier C8AZ-19B546-A or equivalent for Traction-Lock(r) rear axle assemblies. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > All Except 3.73:1 and 4.10:1 > Page 4033 Axle Shaft: Service and Repair 3.73:1 and 4.10:1 REMOVAL AND INSTALLATION 1. Raise and support vehicle. 2. Remove rear wheels and brake drums. 3. Drain rear axle lubricant by removing housing cover. 4. Remove axle shafts as follows: a. Remove pinion shaft lock bolt, place hand behind differential case and push out on pinion shaft until the stop on the shaft contacts the ring gear b. Remove U-washers from axle shafts. c. Carefully slide shafts out of housing. 5. Remove seal and bearing using a suitable hook-type puller. 6. Reverse procedure to install, noting the following: a. Apply suitable grease between lips of axle shaft seal. b. Install bearing using axle tube bearing replacer tool No. T78P-1225-A, and install seal and using axle tube seal replacer tool No. T78P-1177-A or equivalents. c. Tighten differential pinion shaft lock bolt to 15-30 ft lb Housing cover bolts to 25-35 ft lb Housing cover ratio tag bolt to 15-24 ft lb. NOTE: Whenever a plastic axle housing cover is removed, it must be replaced with a new cover and bolts. On plastic axle housing covers torque bolts to 15-20 ft lb. d. Add rear axle lubricant EOAZ-19580-AA or equivalent until it is 6-14 mm (1/4 - 9/16 inch) below the fill hole. Add 4oz. of friction modifier C8AZ-19B546-A or equivalent for Traction-Lock(r) rear axle assemblies. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments REMOVAL AND INSTALLATION 1. Raise and support front of vehicle. 2. Remove wheel cover, grease cap, cotter pin and locknut. 3. Loosen adjusting nut 3 turns, then lock wheel assembly in and out several times to push brake shoe and linings away from rotor. 4. Torque adjusting nut to 17-25 ft lb while rotating wheel assembly. 5. Loosen adjusting nut 1/2 turn, then retorque to 18-20 inch lbs. 6. Install locknut and cotter pin. 7. Ensure wheel assembly rotates smoothly, then reinstall grease cap and wheel cover and lower vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips Wheel Hub (Locking): Technical Service Bulletins Automatic Hublock - Diagnosis/Service Tips Article No. 95-5-18 03/13/95 ^ LOCK HUBS - 4WD - AUTOMATIC HUBLOCK INFORMATION - SERVICE TIPS ^ FOUR-WHEEL DRIVE (4WD) - AUTOMATIC LOCK HUB DIAGNOSIS LIGHT TRUCK: 1983-90 BRONCO II 1983-95 RANGER 1991-94 EXPLORER ISSUE: 4X4 system diagnosis can be difficult at times due to system complexities. ACTION: For general system operation and diagnosis: Refer to TSB Article No. 92-1-8. For specific automatic lock hub diagnosis and service: Refer to this article. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 4041 HUBLOCK DIAGNOSTICS WHEEL END CONTAMINATION: ^ All compact vehicle hublocks have an O-ring seal between the hublock and wheel hub to prevent contamination. Whenever the hublock is removed, the 0-ring seal should be checked for damage. ^ If contamination is found in the wheel end, the path must be determined and corrected. Path possibilities are through the hublock seal, the wheel bearing seals or the axle spindle seals. WHEEL END NOISE (BUZZING) IN 4X2, AFTER UNLOCKING HUBS, SHORTLY AFTER FOUR-WHEEL DRIVE USAGE: ^ Noise concerns in two-wheel drive shortly after shifting from four-wheel drive and unlocking hubs, can occur if one of the hublocks fails to disengage. As the vehicle moves forward, the one (1) hublock that has failed to disengage will rotate its axle shaft through the differential and attempt to rotate the other axle shaft in the opposite direction. This is called differential motoring torque. As this torque attempts to turn the other axle shaft through the differential gears, that shaft's hublock will attempt to engage which will result in a ratcheting or buzzing noise. ^ This type of noise concern is usually found on axles that have incorrect front axle differential lubricant or very few 4X4 miles on them. ^ Verify that the front axle differential lubricant is F1TZ-19580-A. If incorrect lubricant is detected, extract the old lubricant using a suction gun. NOTE: BREAKING THE CARRIER SEAL IS NOT A RECOMMENDED METHOD OF EXTRACTING THE LUBRICANT. 1. Refill the front axle with 56 oz (1.66 L) of lubricant F1TZ-19580-A using a suction gun. 2. As the front axle accumulates 100-200 miles (161-322 km) of locked hublock operation, the axle will break-in, thus reducing the amount of differential motoring torque significantly. 3. If a front axle requires breaking in, refer to the Front Axle Break-In Procedure in this article. 4. If the front axle has been broken-in and the differential lubricant is F1TZ-19580-A, however, a wheel end noise (buzzing) in 4X2 is still experienced shortly after four-wheel drive usage. It is advised that the hublock which is not ratcheting be replaced as it is not disengaging correctly. When this condition occurs on any 4X4 Ranger, Explorer, or Bronco II, built from 10/89 through model year 1993, it is advised that both hublocks be replaced as the ratcheting hub is likely to become damaged. FRONT AXLE BREAK-IN PROCEDURE: ^ To break-in the front axle, engage four-wheel drive and then shift out of it without disengaging the hublocks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 4042 ^ Thereafter, continue to drive the vehicle with locked hublocks until 100-200 miles (161-322 km) are accumulated. This will break-in the axle. Should the vehicle be backed up during this time period, the hublocks will disengage and will have to be locked again by repeating the engagement procedure. WHEEL END NOISE (RATCHETING) IN 4X2 AND HUBS UNLOCKED: ^ This condition could occur during turns or when the suspension is stroked. It is more prevalent in cold weather, with new front axles. It is usually caused by high motoring torque at the axle shafts or by incorrect axle lubrication. ^ Verify that axle lubrication is F1TZ-19580-A. If the front axle is not broken-in, 100-200 4X4 miles (161-322 km), proceed to do so following the outlined front axle break-in procedure in the Hublock Diagnostics section of this TSB article. WHEEL END NOISE (BUZZING) WHILE ENGAGING 4X4 (TOUCH DRIVE) WHILE MOVING: ^ Refer to TSB Article No. 91-15-10. POPPING/BANGING SOUND WHILE IN 4X4: ^ If the system slips under load, find what has broken or is slipping. To locate where slip is taking place, put marks at various possible slip points (Figure 1). Test drive the vehicle, then check to see if marks at different points are still in the same relationship to each other. This will help you determine where the slippage is taking place or where to look for broken parts, if any. ^ On vehicles with automatic hubs, find a place where you can do your test, mark the components, then drive without backing up. Stop and check the marks to see if they are in the same relationship to each other. If you back up before checking your marks, the hubs may reindex and not reveal the problem. ^ Reindex component should be serviced. INSTALLATION PROCEDURE 1. Remove old hublock; remove key from bearing retainer nut and then remove nut. 2. If replacing a manual hublock with an automatic hublock, also remove the three-piece wheel bearing nut assembly. 3. Remove the new wheel bearing retaining nut from the cam assembly and install on the threaded spindle. 4. Using Hex Locknut Wrench (T70T-4252-B), torque the wheel bearing retainer nut to 47 N-m (35 lb.ft.) while rotating the wheel assembly. Back nut off 1/4 turn and retighten to 1.8 N-m (16 lb.in.) of torque. 5. Align scallop of the wheel bearing retaining nut with the center of the spindle keyway by advancing the nut clockwise. 6. Install the retaining key into the spindle keyway. With the garter spring inboard, align the key on the cam assembly with the keyway on the spindle. 7. Firmly press the cam assembly on the wheel bearing retaining nut. CAUTION: DO NOT PACK THE HUBLOCK WITH GREASE. TOO MUCH GREASE WILL CAUSE IMPROPER HUBLOCK OPERATION AND MAY DAMAGE THE HUBLOCK. 8. For Ranger and Bronco II, model years 1983-90 (through build date 10/4/89), using the DANA 28 Axle, install the thrust washer set onto the axle: a. First, the plain steel washer. b. Second, the needle bearing. c. Last, the spline washer. 9. For model years 1990-94 (begin build date 10/5/89), DANA 35 Axle, install the one-piece spline washer. Install the "C" clip into the axle groove. It may be necessary to push the axle outboard from the inboard side of the knuckle. 10. For 1995 Ranger, install the thrust washer onto the axle: a. First, the plain steel thrust washer. b. Second, the plastic unsplined thrust washer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 4043 c. Last, the steel spline thrust washer. CAUTION: ENSURE THE RETAINING RING OR "C" CLIP IS SEATED PROPERLY IN THE AXLE GROOVE FOR STEPS 8, 9, OR 10. 11. Check to ensure 0-ring seal on the flange face of the hublock body is not damaged and is properly positioned in its groove. 12. Install the hublock body assembly into the vehicle hub and rotor assembly. The hub may have to be rotated to line up the three (3) prongs of the cam follower (found internally to the hublock) with the cam assembly. 13. Install retainer flat nuts on wheel studs. NOTE: DO NOT FORCE THE HUBLOCK ASSEMBLY. IF THE BODY ASSEMBLY WILL NOT FIT, RECHECK THE ALIGNMENT OF ALL COMPONENTS. INSTALL SPEEDNUTS ON WHEEL LUGS TO RETAIN HUBLOCK. THEREAFTER, INSTALL THE WHEEL AND TORQUE THE LUG NUTS TO 136 N-m (100 LB.FT.) (FIGURE 2). HISTORY AND TIMING The Warn Automatic Hublock (Model M350) was used on the DANA 28 Axle (Bronco II and Ranger) from model years 1983-90 (through build date 10/4/89). The Warn Automatic Hublocks (Models M350A and M350B) were used on the DANA 35 Axle (Bronco II, Explorer and Ranger) for model years 1990-93 (begin build date 10/5/89). Starting with model year 1994 the Warn Automatic Hublock (Model M350C) used on the DANA 35 Axle (Explorer and Ranger) was introduced. The Model M350 is black and Model M350A, M350B and M350C are argent (white silver) in color. The Model M350 can only be replaced by Model M350 service parts. The M350C service kits should be used as replacements for the following: ^ M350A hublocks released 10/89 as model year 1990 running change. ^ M350B hublocks released 4/92 as model year 1992 late running change. ^ M350C hublocks released 8/93 as model year 1994 Job 1 change. When automatic hublock servicing is required for any Ranger, Explorer, or Bronco II built from 10/89 through model year 1993, it is advised that both hublocks be replaced. NOTE: IF AN M350A OR M350B HUBLOCK REQUIRES SERVICING, ALL THE HUBLOCK COMPONENTS MUST BE REMOVED AND REPLACED WITH SERVICE KIT F3TZ-3B396-B, WHICH ESSENTIALLY IS THE SERVICE KIT FOR THE M350C AUTOMATIC HUBLOCK. THE CAM ASSEMBLY OF THE M350A OR M35OB SHOULD NOT BE USED WITH AN M350C AUTOMATIC HUBLOCK BODY NOR SHOULD AN M350A OR M350B AUTOMATIC HUBLOCK BODY BE USED WITH AN M350C CAM ASSEMBLY. For model year 1994 (and beyond) 4X4 Rangers or Explorers, replace automatic hublocks in accordance with the automatic hublock Service Manual procedure and additional diagnostics procedure outlined in this TSB. IDENTIFYING AUTOMATIC HUBLOCK MODELS A stamped code found on the rear of the automatic hublock flange face can be used to identify the automatic hublock type, in addition to the model year summary described above. Examples of the three (3) different codes which correlate to the automatic hublock model type are outlined in the chart: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 4044 THE ABOVE PART APPLICATION CHART IS FOR 1983-90 (THROUGH BUILD DATE 10/4/89) BRONCO II, RANGER, DANA 28 AXLE, HUBLOCK MODEL M350: THE ABOVE PART APPLICATION CHART IS FOR: ^ 1990-95 Ranger (begin build date 10/5/89) ^ 1990 Bronco (begin build date 10/5/89 through end of production) ^ 1991-94 Explorer (through build date 11/18/94, DANA 35 Axle, Hublock Model M350C) OTHER APPLICABLE ARTICLES: 92-1-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 508000, 509000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability Universal Joint: Technical Service Bulletins Universal Joint - Greasable Design Availability Article No. 97-20-15 09/29/97 ^ DRIVESHAFT - U-JOINT - AVAILABILITY OF GREASEABLE SERVICE PARTS ^ DRIVESHAFT - U-JOINT - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT ^ DRIVESHAFT - U-JOINTS - IDENTIFICATION OF SERVICE PARTS BY MEASUREMENT LIGHT TRUCK: 1990-96 BRONCO 1990-97 AEROSTAR, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-97 EXPLORER 1997 EXPEDITION, MOUNTAINEER ISSUE: Available U-joints for driveshaft service are not always identifiable through model application charts. Some customers may request greaseable U-joints as a personal preference. ACTION: Refer to the following Service Information for availability of U-joint with grease fittings. SERVICE INFORMATION TO IDENTIFY U-JOINT BY MEASUREMENT: 1. Remove the old U-joint. 2. Measure U-joint using the following measuring procedure. a. Remove bearing cups. b. Remove excess grease from bottom of bearing cups and trunnions. c. Remove seals from bearing cups and trunnions. d. Reinstall bearing cups on trunnions. e. Measure as follows, permitting a tolerance of 10.005" at Dimension "G" in Figure 1 with Dimension "D" and "E" at 10.003". Outside Snap Ring Style (Figure 1) A) Measure "G" dimension and record. B) Measure "D" dimension and record. C) Measure "E" dimension and record, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Universal Joint - Greasable Design Availability > Page 4050 3. Identify U-joint part number using reference dimensions in the Light Truck Cross Reference Chart found at the end of this TSB article. TO IDENTIFY GREASEABLE U-JOINT FOR SERVICE: For customers who demand greaseable U-joints due to their specific vehicle duty cycle, refer to Light Truck Cross Reference Chart found at the end of this TSB article. Greaseable U-joints are typically recommended only for vehicles which operate 100% of the time in a high grit environment (e.g., coal mines). NOTE: GREASEABLE U-JOINTS DO NOT CONTAIN END PLAY THRUST WASHERS AND MAY CAUSE NOISE/VIBRATION/HARSHNESS (NVH) CONCERNS ON CERTAIN APPLICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 509000, 590000, 597997 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Customer Interest for Flex Plate: > 02-14-2 > Jul > 02 > Engine - Noise/Vibration/No Crank/No A/T Engagement Flex Plate: Customer Interest Engine - Noise/Vibration/No Crank/No A/T Engagement Article No. 02-14-2 07/22/02 ^ ENGINE - 4.0L OHV - POSSIBLE CRACKED FLEXPLATE - NOISE OR VIBRATION VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION ONLY ^ ENGINE - NO CRANK - POSSIBLE CRACKED FLEXPLATE - NOISE OR VIBRATION VEHICLES EQUIPPED WITH 4.0L ENGINE AND AUTOMATIC TRANSMISSION ONLY ^ NOISE - NOISE DURING CRANKING - POSSIBLE CRACKED FLEXPLATE - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE AND AUTOMATIC TRANSMISSION ONLY ^ TRANSMISSION - A4LD - 4R55E - NO FORWARD OF REVERSE ENGAGEMENT - POSSIBLE CRACKED FLEXPLATE - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1991-1996 AEROSTAR, EXPLORER, RANGER ISSUE Some vehicles equipped with an automatic transmission and a 4.0L OHV engine may exhibit a noise/vibration, no drive, unusual noise during cranking or a no crank condition. This may be caused by a crack in the flexplate. ACTION Verify that one of the conditions exists. if the condition is verified and the flexplate has been isolated as the cause, replace the flexplate with revised Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Customer Interest for Flex Plate: > 02-14-2 > Jul > 02 > Engine - Noise/Vibration/No Crank/No A/T Engagement > Page 4059 Service Part F1TZ-6375-BA (Figure 1). Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. 1. Verify that one of the conditions exist; noise/vibration, no drive, unusual noise during cranking 6r a no crank condition. 2. Verify that the starter operates properly. If not, service as necessary, then recheck if one of the other conditions still exist. 3. If the one of the conditions still exist and the flexplate has been. isolated as the cause, the flexplate will have to be replaced with revised part F1TZ-6375-BA (Figure 1). 4. Following the procedures listed in the appropriate year Workshop Manual, Engine Section 03, In-Vehicle Service, Flywheel, replace the Automatic Transmission Flexplate. 5. After completing the replacement procedure, check the transmission fluid level and adjust if necessary to the proper level. 6. Verify service. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000, 504000, 597997, 601300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flex Plate: > 02-14-2 > Jul > 02 > Engine - Noise/Vibration/No Crank/No A/T Engagement Flex Plate: All Technical Service Bulletins Engine - Noise/Vibration/No Crank/No A/T Engagement Article No. 02-14-2 07/22/02 ^ ENGINE - 4.0L OHV - POSSIBLE CRACKED FLEXPLATE - NOISE OR VIBRATION VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION ONLY ^ ENGINE - NO CRANK - POSSIBLE CRACKED FLEXPLATE - NOISE OR VIBRATION VEHICLES EQUIPPED WITH 4.0L ENGINE AND AUTOMATIC TRANSMISSION ONLY ^ NOISE - NOISE DURING CRANKING - POSSIBLE CRACKED FLEXPLATE - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE AND AUTOMATIC TRANSMISSION ONLY ^ TRANSMISSION - A4LD - 4R55E - NO FORWARD OF REVERSE ENGAGEMENT - POSSIBLE CRACKED FLEXPLATE - VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1991-1996 AEROSTAR, EXPLORER, RANGER ISSUE Some vehicles equipped with an automatic transmission and a 4.0L OHV engine may exhibit a noise/vibration, no drive, unusual noise during cranking or a no crank condition. This may be caused by a crack in the flexplate. ACTION Verify that one of the conditions exists. if the condition is verified and the flexplate has been isolated as the cause, replace the flexplate with revised Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Flex Plate: > 02-14-2 > Jul > 02 > Engine - Noise/Vibration/No Crank/No A/T Engagement > Page 4065 Service Part F1TZ-6375-BA (Figure 1). Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS. 1. Verify that one of the conditions exist; noise/vibration, no drive, unusual noise during cranking 6r a no crank condition. 2. Verify that the starter operates properly. If not, service as necessary, then recheck if one of the other conditions still exist. 3. If the one of the conditions still exist and the flexplate has been. isolated as the cause, the flexplate will have to be replaced with revised part F1TZ-6375-BA (Figure 1). 4. Following the procedures listed in the appropriate year Workshop Manual, Engine Section 03, In-Vehicle Service, Flywheel, replace the Automatic Transmission Flexplate. 5. After completing the replacement procedure, check the transmission fluid level and adjust if necessary to the proper level. 6. Verify service. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 499000, 504000, 597997, 601300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Page 4066 Flex Plate: Specifications Flywheel to Crankshaft 59 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel to Crankshaft 59 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4076 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4077 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4078 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4079 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4080 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4081 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4082 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4083 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair Case: Service and Repair UNDER 8500 GVW - WITH M5OD, 5-SPEED DISASSEMBLE Removing Dust Cover 1. Place top cover in a suitable holding fixture. 2. If necessary, remove dust boot, then lift shift lever from top cover. 3. Remove three dust cover retaining screws, then the dust cover. To facilitate installation, note grooves in bushings aligned with slots in lower shift lever faces toward front of transmission. 4. Invert top cover on holding fixture, then remove back-up lamp switch and back-up lamp switch pin. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair > Page 4088 Removing Shift Forks 5. Remove spring pins retaining shift forks to shift rails, then discard spring pins. 6. Ensure 5th/reverse shift rail is in full forward position, then remove spring pin from end of 5th/reverse rail. Cross-sectional View Of Shift Rail Assembly 7. Remove three rubber plugs blocking shift rod service bores. CAUTION: To prevent component loss when performing the following procedures, cover lock balls, friction device, and spring seats with a suitable clean cloth held firmly in place. Wear safety glasses during shift rail removal. 8. Remove 5th/reverse shift rail from top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining rearward pressure. 9. Remove 3rd/4th shift rail from top cover through service bore. If necessary, insert a suitable drift through spring pin bore and gently rock shift rail from side to side while maintaining rearward pressure. Removing 5th/Reverse Cam Lockout Plate 10. Remove 5th/reverse cam lockout plate retaining bolts, then the 5th/reverse cam lockout plate. ASSEMBLE 1. Place top cover in a suitable holding fixture. 2. Position 5th/reverse cam lockout plate to top cover. Install 5th/reverse cam lockout plate retaining bolts, then torque to 6-7 ft lbs. 3. Position 3rd/4th shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair > Page 4089 4. Engage 3rd/4th shift fork with shift rail, then position detent ball and spring into top cover spring seats. 5. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball. 6. Position friction device and spring into top cover spring seats. 7. Compress friction device and spring assembly, using a suitable tool, then push shift rail into position over friction device. 8. Install 3rd/4th shift fork to shift rail retaining spring. 9. Position 1st/2nd shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure. 10. Engage 1st/2nd shift fork with shift rail, then position detent ball and spring into top cover spring seats. 11. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball. 12. Position friction device and spring into top cover spring seats. 13. Compress friction device and spring assembly, using a suitable tool, then push shift rail into position over friction device. 14. Install 1st/2nd shift fork to shift rail retaining spring. 15. Position 5th/reverse shift rail into top cover through service bore. If necessary, insert a 5/16 inch drift punch through spring pin bore and gently rock shift rail from side to side while maintaining forward pressure. 16. Engage 5th/reverse shift fork with shift rail, then position detent ball and spring into spring seats. 17. Compress detent ball and spring assembly, using a suitable tool, then push shift rail into position over detent ball. 18. Install shift rail to top cover spring pins, then the 5th/reverse shift fork to shift rail retaining spring pin. 19. Install rubber plugs into service bores. 20. Insert interlock pins into 1st/2nd and 3rd/4th shift rails. Ensure large and small interlock pins are installed into their original positions. Improper installation of interlock pins will prevent activation of neutral switch and/or back-up lamp switch. 21. Apply a suitable sealant to back-up lamp switch and neutral switch threads. Install switches in top cover, then torque to 18-26 ft lbs. 22. Position lower shift lever and dust cover assembly into top cover, then install three retaining screws and torque to specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Testing and Inspection Countershaft: Testing and Inspection UNDER 8500 GVW - WITH M5OD, 5-SPEED INSPECTION Check countershaft gear teeth and countershaft splines for wear or damage. If bent, worn or scored, replace countershaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Testing and Inspection > Page 4093 Countershaft: Service and Repair UNDER 8500 GVW - WITH M5OD, 5-SPEED REMOVAL Removing Countershaft Center Bearing Inner Race 1. Remove countershaft center bearing inner race, using a suitable press and bearing cone remover tool No. T71P-4621-B or equivalent. Removing Countershaft Rear Bearing Inner Race 2. Remove countershaft front bearing inner race, using bearing splitter tool No. D84L-1123-A or equivalent. INSTALLATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Testing and Inspection > Page 4094 Installing Countershaft Center Bearing Inner Race 1. Install center bearing inner race, using bearing replacer tool No. T53T-4621-B or equivalent. Installing Countershaft Front Bearing Inner Race 2. Install countershaft front bearing inner race, using bearing replacer tool No. T53T-4621-B or equivalent. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Testing and Inspection Extension Housing: Testing and Inspection UNDER 8500 GVW - WITH M5OD, 5-SPEED INSPECTION Check extension housing for cracks. Ensure machined mating surfaces are free from burrs, nicks, or any other damage. If necessary, replace oil seal after extension housing has been installed onto transmission. NOTE: Extension housing rear bushing cannot be serviced. If service is required, replace as a unit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 4102 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 4103 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Five-Speed Manual Overdrive Transmission (Ford Manual Transmission) Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX (E4XZ-19582-B) or Equivalent ..... .............................................................................................................................................................. .............. 5.6 Pints (US) (2.65 Liters) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4106 Fluid - M/T: Fluid Type Specifications Five-Speed Manual Overdrive Transmission (Ford Manual Transmission) Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX (E4XZ-19582-B) or Equivalent ..... .............................................................................................................................................................. .............. 5.6 Pints (US) (2.65 Liters) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Testing and Inspection Synchronizer Ring: Testing and Inspection INSPECTION 1. Inspect gear teeth on synchronizer ring. If evidence of chipping or excessively worn teeth are present, replace component. Checking Synchronizer Ring 2. Check synchronizer ring for wear by assembling synchronizer ring to gear cone. 3. Measure clearance between side faces of synchronizer ring and gear using a suitable feeler gauge. If clearance is less than 0.031 inch, replace synchronizer ring or gear, 1st/2nd, 3rd/4th, and 5th/reverse synchronizer to gear clearance specifications are the same. 4. Check for proper contact between inner surface of synchronizer ring and cone surface of gear by applying a thin coat of Prussian blue or equivalent to surface of cone, then fitting it into ring. If contact pattern is poor, correct by applying compound and lapping surfaces together. 5. Ensure clutch sleeve slides easily onto clutch hub. 6. Check synchronizer inserts (keys), inner surface of clutch sleeve, then the insert groove on clutch hub from wear. 7. Check synchronizer insert spring for tension. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Testing and Inspection Input Shaft: Testing and Inspection WITH M5OD, 5-SPEED - WITH M5OD, 5-SPEED INSPECTION Check input shaft for spline damage. If needle bearing surface in bore of bearing is worn or rough or if cone surface is damaged, replace input shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Testing and Inspection > Page 4114 Input Shaft: Service and Repair 1. Remove and discard plastic scoop ring. Disassembling Input Shaft 2. Press tapered roller bearing from input shaft using bearing remover tool No. T71P-4621-B or equivalent and a suitable press. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Testing and Inspection > Page 4115 Installing Input Shaft Bearing 3. Install input shaft tapered roller bearing, using bearing cone installer tool No. T88T-7O25-B or equivalent. 4. Install new plastic scoop ring onto input shaft, then manually rotate ring clockwise to ensure input shaft oil holes are properly aligned with scoop ring and a click is heard. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Testing and Inspection Output Shaft: Testing and Inspection INSPECTION Checking Synchronizer Ring 1. Check output shaft runout by placing output shaft in V-blocks. 2. Mount a suitable dial indicator next to shaft, then measure runout at several points along shaft. 3. Total output shaft runout should not exceed 0.002 inch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Testing and Inspection > Page 4119 Output Shaft: Service and Repair DISASSEMBLE Positioning output Shaft For Component Replacement 1. Position output shaft front flange as shown, then remove pilot bearing, snap ring, needle bearing, and front spacer. Output Shaft Components 2. Position front (short side of flange) of output shaft facing upward, then lift off clutch hub and sleeve assembly (3rd/4th), synchronizer ring (3rd) and needle bearing as an assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Testing and Inspection > Page 4120 Removing Output Shaft Components 3. Position output shaft with rear end facing upward on a suitable press as shown. 4. Press off center bearing, 1st gear sleeve, 1st gear, needle bearing, 1st/2nd clutch hub, and sleeve assembly, 1st/2nd synchronizer rings, 2nd gear, and needle bearing as an assembly, using a suitable tool. ASSEMBLE Output Shaft Components 1. Position output shaft with long side of flange facing upward, then position output shaft components to facilitate installation as shown in the Exploded View Of Output Shaft image. 2. Assemble 2nd gear needle bearing, 2nd gear, 2nd gear synchronizer ring, 1st/2nd clutch hub and sleeve assembly, 1st gear synchronizer ring, 1st Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Testing and Inspection > Page 4121 gear needle bearing, 1st gear, 1st gear sleeve, and center bearing onto shaft. NOTE: When installing 1st/2nd clutch hub and sleeve, ensure smaller width of sleeve is facing front side of 2nd gear. 3. Press components onto shaft, using bearing replacer tool No. T53T-4621-B and bearing plate tool No. T75L-1165-B or equivalent and a suitable press. 4. Ensure center bearing race is installed into transmission case, then install center bearing onto output shaft. 5. Position output shaft with short side of shaft facing upward on a suitable press, then install 3rd gear needle bearing, 3rd gear, and 3rd gear synchronizer ring. 6. Install 3rd/4th clutch hub and sleeve as follows: a. Mate clutch hub synchronizer key groove with reference mark on clutch hub sleeve. b. Ensure mark is facing rearward. c. Install longer flange on clutch hub sleeve toward 3rd gear. Installing 3rd/4th Clutch Hub NOTE: Front and rear sides of clutch are similar except for reference mark on one side. 7. Install in order, spacer, needle bearing with rollers upward, retaining ring, then the pilot roller bearing. 8. Install original retaining ring. Measuring Clutch Hub. 9. Check clutch hub endplay, using a suitable feeler gauge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Testing and Inspection > Page 4122 3rd/4th Clutch Hub Selective Retaining Ring Chart 10. If necessary, adjust 3rd/4th clutch hub endplay to specifications. Endplay should be 0.0-0.0019 inch. If endplay is not as specified, select a suitable retaining ring from the 3rd/4th Clutch Hub Selective Retaining Ring Chart that will bring end play to within specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Service and Repair Reverse Gear Shaft: Service and Repair REMOVAL Cross-Sectional View Of Reverse Idler Gear Shaft 1. Remove retaining ring, spacer, idle gear, needle bearings, and thrust washer from reverse idler gear shaft. INSTALLATION 1. Install thrust washer onto reverse idler gear shaft. Ensure tab on thrust washer mates with groove on reverse idler shaft to prevent rotation of thrust washer. 2. Install needle bearings, idler gear, and spacer. 3. Install original retaining ring onto reverse idler gear shaft, then insert a suitable feeler gauge between retaining ring and reverse idler gear to measure end play. Reverse Idler Gear Selective Retaining Ring Chart 4. Endplay should be 0.1-0.2 mm (0.0039-0.0078 in). If endplay is not as specified, select a suitable retaining ring from the Reverse Idler Gear Selective Retaining Ring Chart that will bring endplay to within specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection Shift Fork: Testing and Inspection UNDER 8500 GVW - WITH M5OD, 5-SPEED INSPECTION Checking Shift Fork Hub Sleeve 1. Check contact surface of shift fork and clutch hub sleeve for evidence of wear or damage. Measure from shift fork to clutch hub sleeve. Clearance should be 0.031 inch. 2. Check operation of clutch hub sleeve while assembled to hub. 3. Position clutch hub sleeve horizontally, then lift hub approximately 3/4 of the way off the sleeve and release. Hub should slide downward into sleeve on its own. If necessary to push hub into sleeve, service as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Speedometer Gear, M/T > Component Information > Testing and Inspection Speedometer Gear, M/T: Testing and Inspection UNDER 8500 GVW - WITH M5OD, 5-SPEED INSPECTION Check speedometer drive and driven gear shafts for wear or damage. Check 0-ring and oil seals for weakness or damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4149 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4150 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4165 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4166 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4167 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4168 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4169 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4170 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4176 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4177 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4178 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4179 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 4190 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Locations > Page 4191 A4LD Automatic Transmission Solenoids: Description and Operation Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > A4LD Automatic Transmission Solenoids <--> [Shift Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions A4LD Automatic Transmission Solenoids: Diagnostic Trouble Code Descriptions Shift Solenoid 3-4 (SS 3-4) The 3-4 shift solenoid is used to control the 3-4/4-3 shift valve. Transmission Function: Used to shift from third gear to fourth gear, and fourth gear to third gear. Symptoms: Failed "ON," vehicle has lack of acceleration performance at start out. Failed "OFF," No 3-4 upshift or 4-3 downshift. Diagnostic Trouble Codes: 566, 3-4 shift solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Locations > Page 4197 Converter Clutch Override Solenoid: Description and Operation Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Converter Clutch Override Solenoid <--> [Torque Converter Clutch Solenoid, A/T] > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Converter Clutch Override Solenoid: Diagnostic Trouble Code Descriptions Torque Converter Clutch Solenoid (TCC) The torque torque converter clutch solenoid (TCC) is used to control the apply and release of the torque converter clutch. Transmission Function: Used to engage the torque converter clutch. Symptoms: Failed "ON," the torque converter clutch would always be engaged above 30 mph. Failed "OFF," the torque converter clutch will not engage. Diagnostic Trouble Codes: 629, TCC solenoid circuit failure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4211 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4212 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4213 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation OPERATION In addition to controlling engine operation, the Powertrain Control Module (PCM) controls transaxle operation. It does this by manipulating four solenoids -- Torque Converter Clutch (TCC), Shift Solenoid 1 (SS1), Shift Solenoid 2 (SS2), and Shift Solenoid 3 (SS3). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Sensor Graph Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4224 Testing Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4225 Transmission Position Switch/Sensor: Description and Operation PURPOSE The Park/Neutral Position (PNP) switch gives an indication of transmission load to the Powertrain Control Module (PCM). This information is required for adjusting fuel/air ratio and idle speed. OPERATION When the transmission is in gear the PNP switch is normally open. This results in a high voltage on the PNP output pin 30. When the transmission is shifted into neutral or park the PNP switch is closed and ground is applied to PNP output pin 30. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation Transmission Speed Sensor: Description and Operation The Transmission Speed Sensor (TSS), located within the transaxle oil pan, produces AC voltage that is proportional to the speed of the transaxle's forward/reverse drum. Since this drum is mechanically connected to the torque converter, the sensor is also measuring turbine speed. The Powertrain Control Module (PCM) uses this input to determine upshift and downshift points. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations ABS Diode: Locations The system diode is located in the power distribution box. The system diode enables the ABS warning light to illuminate when ignition is ON and the system is disabled by switching the system relay to the default position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations > Page 4238 ABS Diode: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations > Page 4239 ABS Diode: Description and Operation PURPOSE The system diode enables the ABS warning light to illuminate when ignition is ON and the system is disabled by switching the system relay to the default position. LOCATION The system diode is located in the relay box mounted behind the power network box with the system relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions ABS Light: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4246 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4247 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4248 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4249 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4250 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 4251 ABS Light: Electrical Diagrams BRAKE WARNING LIGHT Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Diagrams > Page 4252 ABS Light: Testing and Inspection BRAKE WARNING LIGHT ON POSSIBLE SOURCE(S): ^ Low fluid level. ACTION(S)TO TAKE: ^ Add fluid, check for leaks, and perform system brake bleeding if required. POSSIBLE SOURCE(S): ^ Parking brake applied or not returning completely. ACTION(S)TO TAKE: ^ Release parking brake. POSSIBLE SOURCE(S): ^ Shorted light circuit. ACTION(S)TO TAKE: ^ Correct short in warning circuit. POSSIBLE SOURCE(S): ^ Damaged fluid level switch or float assembly. ACTION(S)TO TAKE: ^ Replace plastic reservoir assembly. POSSIBLE SOURCE(S): ^ Anti-Lock light does self check. ACTION(S)TO TAKE: ^ Refer to Anti-lock Brakes. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures POSSIBLE SOURCE(S): ^ Damaged combination valve. ACTION(S)TO TAKE: ^ Replace as required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #1 Power Distribution Box The 4WABS Relay #1 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 > Page 4257 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #2 Power Distribution Box The 4WABS Relay #2 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 4258 4WABS Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 4259 4WABS Relay: Description and Operation PURPOSE The system relay has two functions, first when the relay is energized, it supplies power to the six valve solenoids in the valve block assembly and the pump motor relay coil. Second, it supplies ground to the ABS warning light when the relay is de-energized. OPERATION The system relay is controlled by the ECU and is energized when it receives an ignition input signal. LOCATION The system relay is located in the fifth position of the relay block behind the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams Acceleration Sensor: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams > Page 4263 Acceleration Sensor: Description and Operation PURPOSE The G-switch detects and indicates to the anti-lock brake control module whether or not the vehicle is moving. OPERATION The G-switch is used on 4x4 vehicles only. When driven in the 4-wheel drive mode all four wheels are mechanically linked and a situation could arise in which one wheel locks up and causes all four wheels to lock up and skid. The speed sensors would indicate the vehicle speed as zero. Without the G-switch, the anti-lock brake control module (2B373) would have no data to compare and would react as if the vehicle were stopped when in fact it is moving. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Pump Motor <--> [Brake Fluid Pump] > Component Information > Locations 4WABS Pump Motor: Locations Component Locations The 4WABS Pump Motor is located at LH side of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Pump Motor <--> [Brake Fluid Pump] > Component Information > Locations > Page 4267 4WABS Pump Motor: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Diagrams > Page 4271 Brake Fluid Pump Relay: Description and Operation PURPOSE This relay supplies power to the pump motor. OPERATION The relay coil receives power from the system relay and is controlled by the ECU by providing ground to the coil ground. LOCATION The pump motor relay is located in the fifth position of the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Data Link Connector <--> [Diagnostic Connector - ABS] > Component Information > Locations 4WABS Data Link Connector: Locations Component Locations The 4WABS Data Link Connector is located at LH side of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Data Link Connector <--> [Diagnostic Connector - ABS] > Component Information > Locations > Page 4275 4WABS Data Link Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations 4WABS Control Module: Locations All Except Limited Edition And Electronic Group The 4WABS Control Module is located in the engine compartment, behind the driver's side headlamp, mounted on the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4279 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4280 4WABS Control Module: Description and Operation PURPOSE The ECU monitors system operation during normal driving as well as during anti-lock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The ECU continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ECU signals the appropriate solenoid valve in the hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the anti-lock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the ECU. This means that once a code is stored, it will be retained by the ECU even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Refer to Diagnosis and Testing. CONSTRUCTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically. LOCATION The Electronic Control Unit (ECU) is located in the engine compartment behind the driver's side headlamp on a bracket mounted on the surface of the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4281 4WABS Control Module: Service and Repair REMOVAL 1. Disconnect positive battery cable. 4WABS Electronic Control Unit Location 2. Locate ECU on carbon canister bracket attached to LH fender inner sheet metal. Disconnect 40-pin connector from ECU. 3. Remove screw retaining ECU to mounting bracket. 4. Gently slide ECU along bracket to free rivet and remove ECU. INSTALLATION 1. Insert rivet into large hole portion of teardrop. Gently slide ECU along bracket to engage rivet. 2. Install retaining screw and tighten to 7-9 Nm (5.2-6.6 ft lb). 3. Connect 40-pin connector and tighten bolt to 5.2-7.2 Nm (3.9-5.3 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Connect positive battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams 4WABS Hydraulic Unit Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4285 4WABS Hydraulic Control Unit: Description and Operation 4WABS Hydraulic Schematic PURPOSE The Hydraulic Control Unit (HCU) is used to control brake hydraulic pressure to prevent wheel lock-up during braking. OPERATION The HCU is located in the front of the engine compartment on the left frame rail. It consists of a valve body assembly, a pump and a motor assembly. During normal braking, fluid from the master cylinder enters the HCU through two inlet ports located at the top of the HCU. The fluid then passes through three normally open inlet valves, one to each wheel in the front and one line to the rear wheels. If the Electronic Control Unit (ECU) senses that a wheel is about to lock, the ECU pulses the appropriate inlet valve which closes that valve. This prevents any more fluid from entering the affected brake. The ECU then looks at that wheel again. If it is still decelerating, the ECU pulses the normally closed outlet valve which decreases the pressure trapped in the line. NOTE: The valve body, the pump and the motor are not serviceable separately. 4WABS Hydraulic Control Unit Item Part Number Description 1. 2B112 Tube 2. 2234 Tube 3. 2C215 Hydraulic Control Unit (HCU) 4. W611633 Screw 5. 2263 Tube 6. 2264 Tube 7. 2B523 Tube 8. N606703 Bolt 9. N801107 U-Nut Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4286 4WABS Hydraulic Control Unit: Service and Repair 4WABS Brake Control System Item Part Number Description 1. 2C018 Electronic Control Unit (ECU) 5. 2C215 Hydraulic Control Unit (HCU) 7. 2234 Tube Assembly 11. 2263 Tube Assembly 12. N802768 Clip 13. 2264 Tube Assembly 14. 2B557 Hose Assembly 15. 2078 Hose Assembly 19. 2C008 Tube Assembly REMOVAL 1. Disconnect positive battery cable. 2. Disconnect 8-pin connector attaching Hydraulic Control Unit (HCU) to wire harness, and disconnect 4-pin connector attaching pump motor to harness. 3. Remove two tubes from inlet ports and three tubes from outlet ports of HCU. Plug each port to prevent brake fluid from spilling on paint and wiring. 4. Remove three nuts retaining HCU assembly to mounting bracket and remove assembly from vehicle. CAUTION: The HCU is not interchangeable with other units. Be sure to replace with correct part. INSTALLATION 1. Insert HCU assembly into mounting bracket. Install three retaining nuts and tighten to 16-24 Nm (12-18 ft lb). 2. Connect three tubes to outlet ports on side of HCU and two tubes to inlet ports on front of HCU. Tighten tube fittings to 14-24 Nm (10-18 ft lb). 3 Connect 8-pin connector and 4-pin connector to harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4287 NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Connect positive battery cable. 5. Perform brake bleeding procedure. Check for fluid leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front Axle Sensor: Diagrams Front Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front > Page 4292 Axle Sensor: Diagrams Rear Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Page 4293 Axle Sensor: Description and Operation PURPOSE The anti-lock brake system uses three sets of variable-reluctance sensors and toothed speed sensor rings to determine the rotational speed of each wheel. OPERATION The sensors operate on magnetic induction principle. As the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the ECU through a twisted-pair wire cable and wiring harness. LOCATION The front sensors are attached to the suspension knuckles, and the speed indicator rings are pressed onto the backside of the rotor. The rear sensor is bolted into the rear axle housing and the rear speed sensor ring is pressed onto the rear axle carrier assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring Axle Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. NOTE: Discard speed sensor ring after removal. Do not reuse old ring. Speed Sensor Ring Removal 4. Using a 3-jaw puller, remove indicator ring from hub. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4296 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 79mm (3.1 in) ID and 96mm (3.8 in) OD, press the ring onto the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear NOTE: To service the speed sensor ring, the differential case must be removed from the axle housing. REMOVAL 1. Remove the bolts retaining the ring gear to the differential case. Remove the ring gear by striking at alternate holes around the gear. CAUTION: Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock brake sensor ring teeth while handling or during assembly. NOTE: ^ Before removing ring gear inspect it and determine if ring runout check is necessary. ^ Do not remove anti-lock speed sensor ring unless replacement is required. It does not have to be removed for ring gear replacement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4297 2. If replacement is required remove the anti-lock brake sensor ring by tapping with a soft-faced hammer. Discard the anti-lock speed sensor ring. CAUTION: The anti-lock speed sensor ring must be discarded upon removal. If removed, a new anti-lock brake sensor ring must be installed. INSTALLATION 1. Position the ring gear and anti-lock speed sensor ring on the differential case. The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case as shown. Start two ring gear retaining bolts through the differential case into the ring gear to make sure case-to-ring gear bolt hole alignment is achieved. CAUTION: ^ Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock speed sensor ring teeth while handling or during assembly. ^ The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case. 2. Press the ring gear and anti-lock speed sensor ring on the differential case using the ring gear as a pilot. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4298 3. Coat the threads of the ring gear retaining bolts with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1. Install the bolts and alternately and evenly tighten to 95-115 Nm (70-85 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4299 Axle Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. From inside engine compartment, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor retaining bolt from front spindle and slide sensor out of mounting hole. INSTALLATION For installation, follow removal procedures in reverse order. Tighten retaining bolt to 4.5-6.8 Nm (40-60 in lb). Rear REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratico■ system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143 mm (0.005-0.045 inches). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft. lbs.). 5. Push the connector on the speed sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Description and Operation Brake Bleeding: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the lines and cause spongy pedal action. This requires the bleeding of the hydraulic system after it has been properly connected to be sure all air is expelled from the brake cylinders and lines. The hydraulic system can be bled manually or with pressure bleeding equipment such as Rotunda(r) brake bleeder 104-00064 or equivalent. Bleed one brake cylinder at a time. Start the bleeding at the right rear brake wheel cylinder and then the left rear wheel brake cylinder. Then proceed to bleed the front brakes, starting with the right front brake and finish bleeding on the left front brake. Keep the brake master cylinder reservoir filled with the specified Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA (ESA-M6C25-A) or equivalent. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoirs filled with the specified brake fluid. Never reuse the fluid that has been drained from the hydraulic system. NOTE: Bleed the primary and secondary hydraulic brake systems separately. Master Cylinder Reservoir 1. On the brake master cylinder reservoir, loosen the master cylinder-to-hydraulic line fittings. 2. Wrap a shop cloth around the tubing below the fitting to absorb escaping brake fluid. 3. Push the brake pedal down slowly to the floor of the cab. This will force air trapped in the brake master cylinder reservoir to escape at the fitting. 4. Hold the brake pedal down and tighten the fitting. Release the brake pedal. NOTE: Do not release the brake pedal until the fitting is tightened or air will re-enter the brake master cylinder reservoir. 5. Repeat this procedure until air ceases to escape at the fitting. Wheel Cylinder Bleeding 6. Place a box wrench on the bleeder fitting on the rear anti-lock brake system valve. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly around the bleeder fitting. a. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. b. Slowly press the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. c. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 7. Place a box wrench on the right brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4305 around the bleeder fitting. 8. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. 9. Slowly push the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. 10. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 11. Repeat this procedure at the left brake wheel cylinder on the opposite side. Refill the brake master cylinder reservoir after each wheel cylinder is bled. 12. Bleed the front brakes starting with the right front brake and then the left front brake as described in Steps 7-11 of this procedure. 13. When the bleeding operation is complete, fill the brake master cylinder to the maximum level line of the brake master cylinder reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4306 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes, get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Be sure the bleeder tank contains enough specified brake fluid (Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA [ESA-M6C25-A] or equivalent), to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi) of air pressure. Never exceed 345 kPa (50 psi) of pressure. Never re-use brake fluid that has been drained from the hydraulic system. NOTE: Bleed the longest line first. 1. Clean all dirt from the brake master cylinder filler cap. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 2. Remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool, Rotunda Brake Bleeder model 104-00064 or equivalent to the brake master cylinder, and attach the bleeder tank hose to the fitting on the adapter. 3. Place a 3/8-inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly around the bleeder fitting. 4. open the valve on the bleeder tank to admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube on the wheel cylinder in a partially filled container of clean brake fluid. Loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. Move on to the left rear, the right front, and finally left front. 7. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 8. Remove the pressure bleeder adapter tool. Fill the brake master cylinder reservoirs to the maximum level line. Install the brake master cylinder filler cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4307 Brake Bleeding: Service and Repair Priming Brake System NOTE: When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir (2K478), and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b. On the brake master cylinder, loosen the rearmost brake tube fitting with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fitting. 7. If any of the brake tubes, disc brake calipers, or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. 8. To gravity bleed the brake system: a. Fill the brake master cylinder with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. b. Loosen both of the rear bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws to 7-9 Nm (62-79 in- lb). Tighten rear caliper bleed screws to 17-24 Nm (13-17 ft-lb). d. One at a time, loosen the front caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the front caliper bleeder screws to 17-24 Nm (13-17 ft-lb). 9. After the brake system has been primed, bleed the brake system at each wheel. NOTE: Keep the brake master cylinder reservoir filled with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4308 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: The anti-lock brake system must be bled in two steps. 1. The brake master cylinder and Hydraulic Control Unit must be bled using Anti-lock Brake Adapter T90P-50-ALA and Jumper T93T-50-ALA. If this procedure is not followed, air will be trapped in the HCU which eventually leads to a spongy brake pedal. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1. T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2. -- Bleed/Harness Selector (Part of T90P-50-ALA) 3. -- Green "Motor On" Lamp (Part of T90-50-ALA) 4. -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5. -- Valve Button (Part of T90P-50-ALA) 6. -- Abort Button (Part of T90P-50-ALA) 7. -- Motor Start Button (Part of T90P-50-ALA) 2. To bleed the brake master cylinder and HCU, disconnect the 40-pin plug from the Electronic Control Unit and install the anti-lock brake adapter to the wire harness 40-pin plug. a. Place the bleed/harness selector in bleed position. b. Turn the ignition switch (11572) ON. At this point the red OFF indicator on the adapter should turn on. c. Push the motor button on the adapter down. This starts the pump motor. The red OFF indicator turns off and the green ON indicator turns on. The pump motor will run for 60 seconds once the motor button is pushed (you do not need to hold the button down). If the pump motor is to be turned off for any reason before this 60 seconds has elapsed, push the abort button and the pump motor will turn off. d. After the first 20 seconds have passed, push and hold the valve button for 20 seconds. This bleeds any trapped air from the brake master cylinder and HCU. e. The pump continues to run for an additional 20 seconds after the valve button is released. 3. Bleed the brake lines in the following order: ^ Right rear ^ Left front ^ Left rear ^ Right front Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments Brake Pedal Assy: Adjustments On dual brake master cylinder with power brake booster-equipped vehicles, the brake systems are designed to permit a full stroke of the brake master cylinder when the brake pedal is fully depressed. A brake pedal clearance adjustment is not required. If pedal travel seems restricted, check for obstructions. To release the brakes, fluid must flow back to the brake master cylinder through a return port when pedal pressure is released. To be sure the wheel cylinder piston moves back far enough to expose the return port, free-travel is built into the pedal linkage on standard and power brake boosters. This prevents the wheel cylinder piston from becoming trapped in a partially released position. NOTE: If a problem is suspected, the push rod and brake pedal should be checked to make sure they are not binding. Pedal free-travel is not always perceptible in dash-mounted booster systems, because the operating clearance for the wheel cylinder piston is adjusted at the booster push rod, rather than the pedal linkage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission Brake Pedal Assy: Service and Repair With Automatic Transmission REMOVAL 1. Disconnect the wires to the stoplight switch (13480) located below instrument panel. NOTE: Locking tab must be lifted before connector can be removed. 2. Disconnect wiring harness from the stoplight switch at the connector. Item Part Number Description 1. 2140 Brake Master Cylinder 2. 2L252 Pedal Bracket Assembly 3. 2457 Brake Pedal Pad 4. 02340 Dash Panel (Reference) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 4314 5. 2005 Power Brake Booster 6. 2455 Brake Pedal 7. 13480 Stoplight Switch 8. 382802 Nut 18-33 Nm (13-25 ft lb) 9. 353574 Washer 10. 387957 Brake Master Cylinder Push Rod Bushing 11. 2478 Brake Pedal Shaft 12. 97414 Retaining Ring 3. Remove the hairpin clip, slide the stoplight switch, pushrod, nylon washer and bushing away from the brake pedal. NOTE: It is necessary to remove the vacuum booster input rod and one bushing spacer washer from the brake pedal pin. 4. Remove the washer and the stop light switch by sliding switch up or down. 5. Remove one of the retainers holding the brake pedal shaft (2478) in the bracket. 6. Slide the brake pedal shaft out of the bracket and remove the brake pedal, inner brake master cylinder push rod bushings (2474) and spring washer. 7. Remove the outer brake master cylinder push rod bushings from the bracket. 8. If required, remove the brake pedal pad (2454) from the brake pedal. INSTALLATION 1. If removed, install the brake pedal pad on the brake pedal. 2. Inspect the brake master cylinder push rod bushings for signs of wear or damage and replace if required. Re-lubricate the brake master cylinder push rod bushings with a light coating of SAE 30 engine oil or equivalent. 3. Insert the two outer brake master cylinder push rod bushings in the bracket. Place the brake pedal, inner brake master cylinder push rod bushings and spring washer in position inside the bracket. NOTE: Make sure push rod orientation is correct 4. Insert the brake pedal shaft through the bracket and brake pedal. 5. Install the retainer on the end of the brake pedal shaft. 6. Position stoplight switch so the U-shaped side is nearest the brake pedal and directly over/under the pin. Then slide stoplight switch up/down trapping the vacuum booster input rod and bushing between the switch side plates. 7. Push switch and push rod assembly firmly toward brake pedal arm. CAUTION: When assembling, do not substitute other types of pin clips. Use only factory supplied hairpin clips. 8. Assemble outside white plastic washer to pin and install hairpin clip to hold entire assembly. CAUTION: Stoplamp switch wire harness must have sufficient length to travel with switch during full stroke of brake pedal. If wire length is too short, reroute or repair harness as required. 9. Assemble the connector to the stoplight switch. 10. Check stoplight switch for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 4315 Brake Pedal Assy: Service and Repair With Manual Transmission Item Part Number Description 1. Brake Booster 2. 353574-S36M Washer 3. 2461 Brake and Clutch Pedal Bushing 4. 97414-S Retaining Ring 5. 2455 Brake Pedal 6. 519 Clutch Pedal REMOVAL 1. Disconnect the wires to the stoplight switch located below instrument panel. 2. Remove the hairpin clip, slide the stoplight switch, the push rod, the nylon washer and brake master cylinder push rod bushing away from the brake pedal. 3. Remove the brake master cylinder push rod spacer (2B129) and then the stoplight switch by sliding stoplight switch up or down. NOTE: Since the switch side plate nearest the brake pedal is slotted it is not necessary to remove the vacuum booster input rod and one brake master cylinder push rod bushing from the brake pedal. 4. Remove the stoplight switch from the brake pedal. 5. Disconnect the clutch master cylinder push rod from the clutch pedal (7519). 6. Disconnect the Clutch Pedal Position Switch (CPP Switch) (11A152) from the push rod. 7. Remove the retainer from the brake pedal shaft. 8. Remove the clutch pedal and brake pedal shaft from the bracket. 9. Remove the brake pedal. 10. Remove the spring washer and inner brake master cylinder push rod bushings from the brake pedal. 11. Remove the outer brake master cylinder push rod bushings from the bracket. 12. If required, remove the brake pedal pad from the brake pedal. INSTALLATION 1. If removed, install the brake pedal pad on the brake pedal. 2. Inspect the brake master cylinder push rod bushings for signs of wear or damage; replace if required. Re-lubricate the brake master cylinder push rod bushings with a light coating of SAE 30 engine oil or equivalent. 3. Insert the two outer brake master cylinder push rod bushings in the bracket. 4. Place the brake pedal, inner brake master cylinder push rod bushings and spring washer in position inside the bracket. 5. Insert the clutch pedal and brake pedal shaft through the bracket and brake pedal. 6. Install the retainer on the end of the clutch pedal shaft. 7. Connect the clutch pedal position switch on the push rod. 8. Connect the clutch master cylinder push rod to the clutch pedal. 9. Install the stoplight switch on the brake pedal. 10. Connect the brake booster push rod and stoplight switch to the pin on the brake pedal. 11. Install the brake master cylinder push rod spacer and spring retainer attaching the stoplight switch and push rod to the brake pedal. 12. Connect the wires to the stoplight switch. 13. Adjust the clip on the clutch pedal position switch as necessary. 14. Check unit for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Type Pin-Slider Bolt-On Anchor Caliper Part Number (RH) F57A-2B120-DC Caliper Part Number (LH) F57A-2B121-DC No. Of Piston(s) Per Brake Two Caliper Piston Diameter 1.81 in Effective Radius 4.21 in Caliper Bracket Bolts 74-96 ft.lb Caliper Pin Bolts 38-48 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4320 Brake Caliper: Diagrams ITEM PART NUMBER DESCRIPTION 1. 2C150 Caliper Pins 2. 2208 Wheel Cylinder Bleeder Screw 3. 2B121 Front Disc Brake Caliper 4. 2B115 Piston Seal 5. 2196 Caliper Piston 6. 18K005 Dust Boot 7. 2019 Inner Shoe and Lining (RH) 7. 2C046 Inner Shoe and Lining (LH) 8. 2B164 Brake Shoe Hold Down Spring 9. 2018 outer Shoe and Lining (RH) 9. 2C088 outer Shoe and Lining (LH) 10. - Torque Buttons (Part of 2B121) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Page 4321 Brake Caliper: Description and Operation OPERATION All vehicles are equipped with front disc brake calipers (2B120). Front disc brake calipers use pin rail-type caliper assemblies with a cast iron rotor integral with the front hub assembly. The front disc brake caliper (2B120) consists of a pin slider caliper housing, inner and outer shoe and lining assemblies, and a wheel cylinder piston (2196). The front disc brake caliper slides on two pins which also attach the front disc brake caliper to the front wheel spindle (3105). The caliper housing contains a wheel cylinder piston. The wheel cylinder piston has a molded rubber dust boot on its outer end that is pressed into a cylinder bore groove to prevent cylinder contamination. There is also a rectangular section rubber piston seal located in the cylinder bore providing sealing between the cylinder and wheel cylinder piston. This seal also causes the wheel cylinder piston to retract once the brakes are released. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Front Caliper Assembly Item Part Number Description 1 2B115 Piston Seal 2 2196 Caliper Piston 3 2207 Dust Boot 4 2B120 Disc Brake Caliper 5 2208 Bleeder Screw 6 -- Caliper Bore (Part of 2B120) 7 -- Seal Groove (Part of 2B120) DISASSEMBLY 1. Remove the front disc brake caliper from the vehicle. Place a block of wood over the wheel cylinder piston before applying air pressure to prevent damage to the wheel cylinder piston. WARNING: Use care because the wheel cylinder piston can develop considerable force from pressure build-up. 2. Apply air pressure to the fluid port in the front disc brake caliper with a rubber-tipped nozzle TOOL 7000-DE to remove the wheel cylinder piston. NOTE: If the wheel cylinder piston is seized and cannot be forced from the front disc brake caliper, tap lightly around the wheel cylinder piston while applying air pressure. 3. Remove the dust boot from the front disc brake caliper. 4. Remove the rubber piston seal from the wheel bearing (1240) and discard it. ASSEMBLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4324 1. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove. 2. Coat the wheel cylinder piston wheel cylinder piston with brake fluid. Spread the dust boot over the wheel cylinder piston wheel cylinder piston seating the dust boot in the caliper piston groove. 3. Install the wheel cylinder piston wheel cylinder piston into the cylinder bore. 4. The dust boot flange should set squarely in the outer groove of the caliper bore when the wheel cylinder piston is completely installed. 5. Install the front disc brake caliper over the rotor. Tools Required: ^ Air Nozzle Tool-7000-DE ^ Rubber Tip for Air Nozzle Tool-7000-DD Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4325 Brake Caliper: Service and Repair Inspection INSTALLATION 1. The wheel cylinder piston must be "bottomed out" when installing new shoe and lining assemblies. Be sure that enough fluid has been removed from brake master cylinder (see Step 1 of Removal) to prevent fluid overflow. Bottom out the wheel cylinder piston with an eight-inch C-clamp using a worn-out inner shoe or a block of wood to push against the wheel cylinder piston. 2. Place a new brake shoe hold down spring on the lower end of the inner shoe. Be sure the tabs on the front disc brake caliper are positioned properly and the front disc brake caliper is fully seated. 3. Position the inner shoe and front disc brake caliper in the shoe abutment of the front wheel spindle with the anti-rattle clip tab against the shoe abutment and the loop-type spring away from the front disc brake rotor. 4. Compress the front disc brake caliper and slide the upper end of the shoe in position. WARNING: Outer shoe torque buttons must be solidly seated in caliper holes or temporary loss of brakes may occur. 5. Install the outer shoe, making sure the torque buttons on the shoe are seated solidly in the matching holes in the front disc brake caliper. 6. Make sure the mounting surfaces are free of dirt and corrosion, and lubricate the caliper grooves with Disc Brake Caliper Grease D7AZ-19590-A (ESA-M1C172-A) or equivalent, then position the front disc brake caliper on the front wheel spindle. NOTE: Be sure to install the caliper pins so the retention tabs will be in contact with the front wheel spindle, not the front disc brake caliper. When the upper pin is properly positioned, the retention tabs will be at the top, against the front wheel spindle. When the lower pin is properly positioned, the retention tabs will be at the bottom, also in contact with the front wheel spindle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4326 Caliper Slide Pin Positioning 7. From the caliper outboard side, position the pin between the front disc brake caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face. NOTE: During the installation procedure, do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens, it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle face. Caliper Pin Installation 8. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the front wheel spindle face. Repeat procedure for the lower pin. 9. If removed, install the front brake hose to the front disc brake caliper. 10. If the front brake hose was removed, perform brake bleeding procedures. 11. Install the wheel and tire assembly. Tighten lugnuts to 114-141 Nm (85-105 ft lb). 12. Lower vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation then recheck brake fluid level in brake master cylinder. Fill as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4327 Brake Caliper: Service and Repair Removal NOTE: If the front disc brake calipers are to be removed for service other than to replace brake shoes, fluid removal from the brake master cylinder (2140) may not be required. Removing some fluid will prevent fluid from overflowing from the brake master cylinder when the wheel cylinder piston are pressed into their bores. CAUTION: System contamination may result if anything other than a clean device is used to remove fluid from brake master cylinder. REMOVAL 1. Use a clean siphon or suction hose to remove a portion of the fluid from the brake master cylinder. Discard the removed fluid. 2. Raise the vehicle and install safety stands. Remove a front wheel and tire assembly. CAUTIONS: ^ Do not position C-clamp on the brake shoe hold down spring. Also, do not compress wheel cylinder piston further than is required to disengage torque buttons from front disc brake caliper. Damage to the brake shoe hold down spring will result. Replace shoe if brake shoe hold down spring is bent or damaged. ^ Do not attempt to "bottom" the wheel cylinder piston in the bore at this time. Use an old, worn out brake shoe or block of wood and the C-clamp to bottom the wheel cylinder piston once the front disc brake caliper is removed from front disc brake rotor, and the shoes are removed from the front disc brake caliper. 3. Use an eight-inch C-clamp to move the wheel cylinder piston back into its bore as follows: a. Place the head of the C-clamp against the front disc brake caliper, and the screw end of the C-clamp against the outer shoe below the spring clip. b. Tighten the clamp until the torque buttons just clear the caliper (about 3mm [1/8 inch]). Remove the C-clamp. c. Do not use a screwdriver or similar tool to pry the wheel cylinder piston away from the front disc brake rotor. 4. Clean excess dirt from area around pin tabs. 5. Using Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the caliper pin from the front disc brake caliper as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4328 Caliper Pin Removal a. Position the notched end of the tool against the caliper pin (retention tab half), at a 45° angle from the pin retention tabs. b. Tap the tool with the hammer to compress the retention tabs. c. As the retention tabs are compressed, move the tool to gain a straight approach to the pin, and continue tapping to drive the pin through the caliper/spindle groove. 6. Remove the front disc brake caliper from the rotor. If the front disc brake caliper is to be removed for service, disconnect the brake hose from the front disc brake caliper. If not, secure the front disc brake caliper with wire. NOTE: do not let the front disc brake caliper hang with its weight on the front brake hose (2078). Inner Brake Pad 7. Compress the brake shoe hold down spring and remove the inner shoe from the front disc brake caliper. Outer Pad Removal 8. To remove the outer shoe from the front disc brake caliper, press each ear of the shoe away from the front disc brake caliper, slide the torque Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 4329 buttons out of the retention notches and slide the shoe off. CAUTION: Never attempt to bottom out the wheel cylinder piston with the outer shoe installed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment Technical Service Bulletin # 98-5A-5 Date: 980318 Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^ BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT ^ BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^ Steering wheel vibration/nibble ^ vibration ^ Brake pedal pulsation Brake roughness is caused by: ^ Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts ^ Non-uniform lining transfer ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^ Improved rotor LRO and "dishing" tolerances ^ Ability to machine rear rotors on live axles, except for trucks with dual rear wheels ^ Easier set-up Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4334 Refer to the Service Procedure for details. PART NUMBER PART NAME F6AZ-9L494-AA High Temperature Nickel Anti-Seize Lubricant OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400 Service Procedure 1. Verify concern. 2. Pre-checks to include: ^ Check OASIS and TSBs for vehicle-specific brake/vibration concerns ^ Visually inspect suspension bushings/ball joints ^ Visually inspect tire conditions and pressure ^ Check wheel bearing end-play 3. Remove wheel/tire. 4. Remove caliper. 5. For vehicles with two-piece hub/rotor: a. Mark rotor and wheel stud for proper indexing during reassembly. b. Remove rotor. NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION C 6. Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor. CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFECT 7. Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) surfa 8. For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a. NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, OR SERVICING THE LATHE. 9. Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a. Install hub adapter and silencer belt (where applicable). b. Install cutting lathe. NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c. Adjust lathe oscillation using a dial indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4335 NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d. Center cutting head, adjust cutting bits, install chip deflector. e. Machine rotor. f. Measure and record rotor thickness. NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g. Install dial indicator, measure and record rotor LRO. Remove dial indicator. h. Remove lathe and silencer belt. 10. Remove metal shavings. 11. Remove the adapter. 12. For vehicles with two-piece hub/rotors: a. Remove rotor from hub. b. Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors. c. Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion. d. Match marks on rotor and hub and assemble rotor to hub. 13. Install pads and calipers. NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES ROTOR 14. Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts. 15. Check brake operation before returning to customer. Support Telephone Numbers 1. Lathe Administration Support: (800) 768-8632 2. Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4336 ^ A = Aspire ^ B = Escort/Tracer ^ C = Probe ^ D = Contour/Mystique ^ E = Mustang ^ F = Taurus/Sable ^ G = Thunderbird/Cougar ^ H = Crown Victoria/Grand Marquis ^ I = Continental ^ J = Mark VIII ^ K = Town Car ^ L = Festiva ^ M = Tempo/Topaz Reference list for Pro-Cut light truck labor operations: ^ AA = Villager ^ AB = Windstar ^ AC = Aerostar 4X2 ^ AD = Aerostar 4X4 ^ AE = Ranger 4X2 ^ AF = Ranger 4X4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4337 ^ AG = Explorer/Mountaineer 4X2 ^ AH = Explorer/Mountaineer 4X4 ^ AI = Econoline ^ AJ = F-250 HD/F-350 4X2 ^ AK = F-250 HD/F-350 4X4 ^ AL = F-Super Duty ^ AM = F-150/F-250 LD 4X2 ^ AN = F-150/F-250 LD 4X4 And Bronco ^ AO = Expedition/Navigator 4X2 ^ AP = Expedition/Navigator 4X4 ^ AQ = Super Duty F Series Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4338 Brake Rotor/Disc: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4339 Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Machining Equipment/Warranty Information Article No. 94-25-2 12/12/94 ^ BRAKES - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION ^ BRAKE ROTOR MACHINING - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION FORD: 1979-95 MUSTANG 1981-95 ESCORT 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE, THUNDERBIRD 1991-95 CROWN VICTORIA 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1979-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1988-89 TRACER 1988-95 CONTINENTAL 1989-95 COUGAR 1991-94 CAPRI 1991-95 GRAND MARQUIS, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II 1984-95 RANGER 1986-95 AEROSTAR 1990-95 BRONCO, E-150, E-250, F-150, F-250 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR This TSB is being republished in its entirety to include the 1994 and 1995 model years. ISSUE: On-vehicle caliper-mounted brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness, pulsation and steering wheel nibble will occur when rotors wear unevenly (thickness variation). This article specifically addresses brake roughness, pulsation and steering wheel nibble resulting from disc brake rotor thickness variation induced by rotor runout. ACTION: Use Rotunda On-Vehicle Brake Lathes 104-00129, 104-00130, 168-00004, or 168-00005 to service vehicles with brake roughness. This method is more effective because it allows machining of the rotor while it is still mounted on the vehicle. This improves the overall run-out of the assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4340 Rotunda on-vehicle caliper-mounted brake rotor machining equipment may correct runout if used according to the equipment manufacturer's instructions. Refer to Figures 1 and 2. Machining the rotor with the use of a caliper-mounted brake lathe will be an eligible repair under warranty for the vehicles listed. NOTE: THERE MAY BE ADDITIONAL MANUFACTURERS OF SIMILAR EQUIPMENT. FORD DOES NOT ENDORSE, INDICATE ANY PREFERENCE FOR, OR ASSUME ANY RESPONSIBILITY FOR EQUIPMENT FROM THESE FIRMS, OR FOR ANY SUCH ITEMS WHICH MAY BE AVAILABLE FROM OTHER SOURCES. NOTE: DEALERS THAT HAVE APPROVED ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT ARE REQUIRED TO RESURFACE BRAKE ROTORS UNDER THE BUMPER TO BUMPER COVERAGE PERIOD. IF A DEALER HAS THE ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT, ROTOR REPLACEMENT WILL ONLY BE ALLOWED WHEN THE ROTOR IS BROKEN OR DOES NOT HAVE ENOUGH MATERIAL TO ALLOW TURNING. SUCH REPLACEMENTS MUST BE AUTHORIZED BY SERVICE MANAGEMENT. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Hub-Mount Brake Rotor Machining Equipment > Page 4341 EXCEPTIONS TO THE LAST STATEMENT ARE REAR ROTORS ON THE TOWN CAR, GRAND MARQUIS, CROWN VICTORIA, MUSTANG AND FRONT ROTORS ON F-350, F-47 AND F-53 HEAVY DUTY LIGHT TRUCKS. ON THESE VEHICLES, ROTORS CANNOT BE MACHINED. SERVICE MANAGEMENT AUTHORIZATION IS NOT REQUIRED FOR THESE EXCEPTIONS. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-13-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4342 Brake Rotor/Disc: Specifications Rotor Diameter 10.28 in Minimum Thickness 0.81 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4343 Brake Rotor/Disc: Testing and Inspection NOTES: - Front disc brake rotor minimum thickness must not be less than 20.6mm (0.81in), the number cast on the inside of the front disc brake rotor after refinishing. - The 70mm (2.756 in) gauge ball that is part of T71P-1102-A is used in conjunction with the micrometer gauge bar is required to make this measurement front rotors. - Maximum allowable stock removal of the inner rotor braking surface is determined by the use of Disc Rotor Surface Gauge and Ball T71P-1102-A as follows: PROCEDURE 1. Remove the inner grease retainer and bearing assembly from the hub and rotor assembly. Wipe the inner and outer bearing cups clean. 2. Carefully place the gauge ball in the inner bearing cup (do not drop). 3. Set the micrometer to the baseline setting dimension 6.50mm (0.256 in). 4. Position the micrometer gauge bar on the rotor inner braking surface with the micrometer centered over the ball. To measure the distance between the micrometer baseline setting and the ball, turn the micrometer down to touch the top of the ball, and calculate the difference between the reading and the baseline setting. This distance is equal to the maximum allowable stock removal from the inside braking surface only. If the micrometer end at the baseline setting touches the ball, no additional stock removal is allowed. NOTE: If the micrometer must be retracted from the baseline setting to allow the legs to set on the rotor surface, the rotor has had more than allowable stock removed and the rotor assembly must be replaced. 5. Check the rotor for the maximum amount of stock that can be removed from the rotor thickness. Measure actual rotor thickness with micrometer and subtract minimum allowable thickness 20.6mm (0.81in). Total material removal (combination of both sides) must not exceed this amount. NOTE: If the rotor thickness is less than the minimum, the rotor must be replaced, regardless of the gauge bar and ball measurement. Rotor minimum thickness is also shown on each rotor. 6. Never use a lathe that cuts only one face of the rotor at a time; it must be a simultaneous straddle cut. 7. Set the cutting tool to just contact the high spots on the rotor, then adjust the cutting tool to the minimum depth required to clean up the rotor face. CAUTION: Do not exceed the allowable stock removal for the inner braking surface or total rotor thickness. Before installing the rotor on the spindle, clean all chips from the rotor and flush new grease through the bearing with a bearing packing tool. A new inner grease seal must be coated with wheel bearing grease and installed in the rotor. The rotor must be installed on the same side of the vehicle from which it was removed. Measure the thickness of the brake lining. If the lining thickness at any point on the assembly is less than 1.5mm (1/16-inch) above the backing plate or if the lining shows evidence of brake fluid or oil contamination that is causing a brake pull, replace all four shoe and lining assemblies. Machining 1. Lathe turn the rotor to: ^ Remove rotor scoring, scratching too deep to repair by hand sanding. Deep scoring/scratching usually occurs after brake use with linings fully worn to the rivets. Stock removal must not reduce rotor thickness to below the specified minimum thickness. ^ Correct a shudder/vibration/pulsation condition if due to rotor distortion. Check the wheel bearing adjustment and correct as required and verify if the condition is corrected. If there is any build-up of foreign material on the linings or rotor surfaces, the condition may not be due to rotor distortion. Hand sand the surfaces and determine if the condition is corrected before resorting to lathe turning. Check the lateral runouts of the brake surfaces. Lathe turn the rotor if hand sanding of any foreign matter on friction surfaces does not correct the condition, or if measured runout exceeds0.254mm (0.010 inch) total indicator reading. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 4344 ^ To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut to specifications. Then check to be sure the front disc brake rotor can still be rotated. ^ Clamp a dial indicator to the spindle knuckle assembly so the stylus contacts the rotor approximately 25.4mm (1 inch) from the outer edge. Rotate the rotor one turn (360 degrees) and take an indicator reading. If the reading exceeds 0.08mm (0.003 inch) total lateral runout, replace or resurface the front disc brake rotor. 2. The following requirements must be met when resurfacing front disc brake rotors: ^ Use a disc brake lathe to resurface the front disc brake rotors. Follow the manufacturer's instructions. ^ The minimum overall thickness specification shown on each rotor allows for a 0.762mm (0.030 inch) machining cut plus 0.762mm (0.030 inch) additional wear. If rotor thickness falls below the minimum, it must be replaced. ^ After lathe turning, the finished brake surfaces of the rotor should be flat and parallel within 0.05mm (0.002 in.); lateral runout should not exceed 0.076mm (0.003 inch) total indicator reading. ^ Measure the thickness of the brake linings. If the lining thickness at any point on the assembly is less than 1.5mm (1/16 inch) above the backing plate or if the lining shows evidence of brake fluid or oil contamination that is causing a brake pull, replace all four rear brake shoes and linings (2200). ^ Thickness on each face must be uniform. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation Brake Rotor/Disc: Service and Repair Installation Item Part Number Description 1. 3105 Spindle Assembly (RH) 2. 2B121 Front Disc Brake Caliper 3. 2C150 Caliper Pin 4. 2B160 Front Brake Splash Shield Gasket 5. 2K005 Front Disc Brake Rotor Shield 6. N611171-S2 M6-1.0 x 10 Screw. Tighten to 7-10 Nm (62-89 in lb) 7. 1190 Grease Seal 8. 1201 Front Wheel Bearing Inner Cone and Roller 9. 1102 Front Disc Brake Hub and Rotor 10. 1216 Front Wheel Bearing Outer Cone and Roller 11. 1195 Washer 12. 374504-S100 Nut, 3/4-16 13. 390622-S Nut Retainer 14. N642569-S36 Cotter Pin, must be installed as shown 15. 1131 Hub Grease Cap 16. 2B164 Brake Shoe Hold Down Spring, must be installed on lower end of inner shoe only, with loop facing away from rotor. NOTE: Install caliper pin so retention tabs are in contact with spindle, not caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 4347 Brake Rotor/Disc: Service and Repair Refinishing NOTES: - Front disc brake rotor minimum thickness must not be less than 20.6mm (0.81in), the number cast on the inside of the front disc brake rotor after refinishing. - The 70mm (2.756 in) gauge ball that is part of T71P-1102-A is used in conjunction with the micrometer gauge bar is required to make this measurement front rotors. - Maximum allowable stock removal of the inner rotor braking surface is determined by the use of Disc Rotor Surface Gauge and Ball T71P-1102-A as follows: PROCEDURE 1. Remove the inner grease retainer and bearing assembly from the hub and rotor assembly. Wipe the inner and outer bearing cups clean. 2. Carefully place the gauge ball in the inner bearing cup (do not drop). 3. Set the micrometer to the baseline setting dimension 6.50mm (0.256 in). 4. Position the micrometer gauge bar on the rotor inner braking surface with the micrometer centered over the ball. To measure the distance between the micrometer baseline setting and the ball, turn the micrometer down to touch the top of the ball, and calculate the difference between the reading and the baseline setting. This distance is equal to the maximum allowable stock removal from the inside braking surface only. If the micrometer end at the baseline setting touches the ball, no additional stock removal is allowed. NOTE: If the micrometer must be retracted from the baseline setting to allow the legs to set on the rotor surface, the rotor has had more than allowable stock removed and the rotor assembly must be replaced. 5. Check the rotor for the maximum amount of stock that can be removed from the rotor thickness. Measure actual rotor thickness with micrometer and subtract minimum allowable thickness 20.6mm (0.81in). Total material removal (combination of both sides) must not exceed this amount. NOTE: If the rotor thickness is less than the minimum, the rotor must be replaced, regardless of the gauge bar and ball measurement. Rotor minimum thickness is also shown on each rotor. 6. Never use a lathe that cuts only one face of the rotor at a time; it must be a simultaneous straddle cut. 7. Set the cutting tool to just contact the high spots on the rotor, then adjust the cutting tool to the minimum depth required to clean up the rotor face. CAUTION: Do not exceed the allowable stock removal for the inner braking surface or total rotor thickness. Before installing the rotor on the spindle, clean all chips from the rotor and flush new grease through the bearing with a bearing packing tool. A new inner grease seal must be coated with wheel bearing grease and installed in the rotor. The rotor must be installed on the same side of the vehicle from which it was removed. Measure the thickness of the brake lining. If the lining thickness at any point on the assembly is less than 1.5mm (1/16-inch) above the backing plate or if the lining shows evidence of brake fluid or oil contamination that is causing a brake pull, replace all four shoe and lining assemblies. Machining 1. Lathe turn the rotor to: ^ Remove rotor scoring, scratching too deep to repair by hand sanding. Deep scoring/scratching usually occurs after brake use with linings fully worn to the rivets. Stock removal must not reduce rotor thickness to below the specified minimum thickness. ^ Correct a shudder/vibration/pulsation condition if due to rotor distortion. Check the wheel bearing adjustment and correct as required and verify if the condition is corrected. If there is any build-up of foreign material on the linings or rotor surfaces, the condition may not be due to rotor distortion. Hand sand the surfaces and determine if the condition is corrected before resorting to lathe turning. Check the lateral runouts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 4348 of the brake surfaces. Lathe turn the rotor if hand sanding of any foreign matter on friction surfaces does not correct the condition, or if measured runout exceeds0.254mm (0.010 inch) total indicator reading. ^ To check rotor runout, first eliminate the wheel bearing end play by tightening the adjusting nut to specifications. Then check to be sure the front disc brake rotor can still be rotated. ^ Clamp a dial indicator to the spindle knuckle assembly so the stylus contacts the rotor approximately 25.4mm (1 inch) from the outer edge. Rotate the rotor one turn (360 degrees) and take an indicator reading. If the reading exceeds 0.08mm (0.003 inch) total lateral runout, replace or resurface the front disc brake rotor. 2. The following requirements must be met when resurfacing front disc brake rotors: ^ Use a disc brake lathe to resurface the front disc brake rotors. Follow the manufacturer's instructions. ^ The minimum overall thickness specification shown on each rotor allows for a 0.762mm (0.030 inch) machining cut plus 0.762mm (0.030 inch) additional wear. If rotor thickness falls below the minimum, it must be replaced. ^ After lathe turning, the finished brake surfaces of the rotor should be flat and parallel within 0.05mm (0.002 in.); lateral runout should not exceed 0.076mm (0.003 inch) total indicator reading. ^ Measure the thickness of the brake linings. If the lining thickness at any point on the assembly is less than 1.5mm (1/16 inch) above the backing plate or if the lining shows evidence of brake fluid or oil contamination that is causing a brake pull, replace all four rear brake shoes and linings (2200). ^ Thickness on each face must be uniform. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Installation > Page 4349 Brake Rotor/Disc: Service and Repair Removal Item Part Number Description 1. 3105 Spindle Assembly (RH) 2. 2B121 Front Disc Brake Caliper 3. 2C150 Caliper Pin 4. 2B160 Front Brake Splash Shield Gasket 5. 2K005 Front Disc Brake Rotor Shield 6. N611171-S2 M6-1.0 x 10 Screw. Tighten to 7-10 Nm (62-89 in lb) 7. 1190 Grease Seal 8. 1201 Front Wheel Bearing Inner Cone and Roller 9. 1102 Front Disc Brake Hub and Rotor 10. 1216 Front Wheel Bearing Outer Cone and Roller 11. 1195 Washer 12. 374504-S100 Nut, 3/4-16 13. 390622-S Nut Retainer 14. N642569-S36 Cotter Pin, must be installed as shown 15. 1131 Hub Grease Cap 16. 2B164 Brake Shoe Hold Down Spring, must be installed on lower end of inner shoe only, with loop facing away from rotor. NOTE: Install caliper pin so retention tabs are in contact with spindle, not caliper. REMOVAL 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the front disc brake caliper from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut, washer, and outer bearing, and remove the rotor from the front wheel spindle. 5. If required, remove the front disc brake rotor shield (2K004). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Testing and Inspection Backing Plate: Testing and Inspection WARNING: Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining done on brake linings or pads should be done using proper exhaust-ventilated equipment. NOTE: Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake and Clutch Service Vacuum 091-00001 or Rotunda Brake Parts Washer 065-00016 or an equivalent. INSPECTION 1. Inspect the brake backing plate for correct mounting and securely tightened mounting nuts. Torque to 34-47 Nm (25-35 ft lb) 2. Inspect the brake shoe and lining contact pads (where the brake shoe and lining rests). ^ Deep grooves in the brake shoe and lining contact pads could restrict brake shoe and lining movement. ^ If grooves exist, hand sand the brake shoe and lining contact pads. ^ If the grooves are still present after hand sanding, the backing plates must be replaced. Any attempts to remove the grooves by grinding may result in improper brake shoe and lining to brake drum contact. 3. Inspect all other brake parts and replace any that are worn or damaged. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Elimination Of Sanding Rotors And Drums Brake Drum: Technical Service Bulletins Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^ Rotor thickness variation and lateral runout ^ Lining or foreign material build-up ^ Drum out-of-round NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4358 Brake Drum: Testing and Inspection WARNING: Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining done on brake linings or pads should be done using proper exhaust-ventilated equipment. INSPECTION 1. Use Rotunda Brake/Clutch/Service Vacuum 091-R0001 or equivalent to remove all dust from backing plates and interior of brake drums (1126). 2. A brake drum should be visually inspected and measured with Rotunda Brake Drum Micrometer 104-00046 or equivalent. Before making an inspection or measurement, remove grease, brake fluid, or other contaminants from the brake drum using denatured alcohol. 3. Best shop practice requires measuring every brake drum with a brake drum micrometer regardless of visual inspection. The brake drum micrometer is set to the drum diameter and measures the amount and type of wear. Measure the diameter at various points 45-degrees apart around the brake shoe and lining contact area, and at the bottom of the deepest groove to determine if the brake drum requires replacement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4359 Brake Drum: Adjustments WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Rear brake drums are adjusted automatically by sharply applying brake while alternately driving the vehicle forward and reverse. Brake adjustment occurs during reverse stops only. Manual brake adjustment is required when the brake shoes are relined or replaced, or if the brake shoe adjusting lever cables have malfunctioned. Keep the brake master cylinder reservoir filled with the specified Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA (ESA-M6C25-A) or equivalent. NOTE: Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 4360 Brake Drum: Service and Repair WARNING: Do not inhale dust from brakes or associated components.Inhalation of dust can be injurious to your health. Compressed air or brushes must not be used to clean brakes, brake drums (1126) and associated components. A vacuum cleaner equipped for this purpose should be carefully used to remove any dust. Adherent dust should be removed with a damp rag. Any dust should be contained in a sealed and labeled bag for disposal. Wear an approved high efficiency cartridge or air line respirator and use extra caution to avoid breathing this dust. Always use non-asbestos replacement parts. REMOVAL 1. Raise the vehicle so the wheel is clear of the floor and install safety stands under the axle shaft (4234). 2. Remove the hub cap, if equipped, and wheel (1007). CAUTION: Use of a drum puller or a torch is not recommended. Drum distortion may result. 3. Remove the retaining nut and remove the brake drum. CAUTION: Loosen the adjusting screw only if the brake drum cannot be removed. Do not burr, chip, or damage the notches in the adjusting screw or the self adjusting mechanism will not function properly. 4. If the brake drum is rusted to the axle shaft pilot diameter, use coarse sandpaper or file to remove the rust build-up, then work the brake drum off. Rear Shoe Adjustment NOTES: If the brake drum will not come off, insert a narrow screwdriver through the brake adjusting hole in the brake backing plate (2211), and disengage the adjusting lever from the adjusting screw. While holding the adjusting lever away from the adjusting screw, loosen adjusting screw with Brake Adjusting Tool D81L-1103-C. - If the adjusting screw was loosened, check to be sure the adjusting lever is still properly seated in the shoe web. INSTALLATION 1. If a new brake drum is to be installed, remove the protective coating from the new brake drum with carburetor degreaser. 2. Adjust the rear brakes using adjustment Gauge D81L-1103A. NOTE: Cutting a scored brake drum may be performed as long as the maximum inside diameter is not exceeded. The maximum inside diameter is imbedded on the drum face. 3. Install the brake drum. 4. Install the brake shoe retracting spring (2296). 5. Install the wheel on the axle shaft flange studs against the brake drum, and tighten the lugnuts to 115-155 Nm (85-105 ft lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 98-5A-36 > Mar > 98 > Rear Brakes - Grab/Stick On First Few Applications Brake Shoe: Customer Interest Rear Brakes - Grab/Stick On First Few Applications Article No. 98-5A-36 03/18/98 BRAKES - GRABBING AND/OR STICKING DURING FIRST FEW BRAKE APPLICATIONS AFTER A RAINFALL AND/OR WHEN BRAKES ARE COLD LIGHT TRUCK: 1983-97 RANGER 1991-94 EXPLORER ISSUE: A grabbing and/or sticking condition during the first few brake applications when the brakes are cold or in the morning after an overnight rain may occur on some vehicles. This may be caused by rear brake lining material that is sensitive to humidity. ACTION: Install new design rear brake linings that are made from material that is less sensitive to humidity. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the rear brake shoes. Refer to the appropriate Explorer/Ranger Service Manual, Section 06-02, for removal procedure. 2. Clean the brake assembly and drums. 3. Install new rear brake shoe and lining assemblies per the Parts Block. Refer to the Service Manual, Section 06-02, for installation procedure. 4. Adjust the brakes according to the Service Manual. PART NUMBER PART NAME F77Z-2200-AA Brake Kit (1995-97, 9" Drum) F77Z-2200-BA Brake Kit (1995-97, 10" Drum) F77Z-2200-CA Brake Kit (1983-94, 9" Drum) F77Z-2200-DA Brake Kit (1983-94, 10" Drum) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-97 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 985A36A Replace Rear Brake Shoes 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 2200 69 OASIS CODES: 301000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 98-5A-36 > Mar > 98 > Rear Brakes Grab/Stick On First Few Applications Brake Shoe: All Technical Service Bulletins Rear Brakes - Grab/Stick On First Few Applications Article No. 98-5A-36 03/18/98 BRAKES - GRABBING AND/OR STICKING DURING FIRST FEW BRAKE APPLICATIONS AFTER A RAINFALL AND/OR WHEN BRAKES ARE COLD LIGHT TRUCK: 1983-97 RANGER 1991-94 EXPLORER ISSUE: A grabbing and/or sticking condition during the first few brake applications when the brakes are cold or in the morning after an overnight rain may occur on some vehicles. This may be caused by rear brake lining material that is sensitive to humidity. ACTION: Install new design rear brake linings that are made from material that is less sensitive to humidity. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the rear brake shoes. Refer to the appropriate Explorer/Ranger Service Manual, Section 06-02, for removal procedure. 2. Clean the brake assembly and drums. 3. Install new rear brake shoe and lining assemblies per the Parts Block. Refer to the Service Manual, Section 06-02, for installation procedure. 4. Adjust the brakes according to the Service Manual. PART NUMBER PART NAME F77Z-2200-AA Brake Kit (1995-97, 9" Drum) F77Z-2200-BA Brake Kit (1995-97, 10" Drum) F77Z-2200-CA Brake Kit (1983-94, 9" Drum) F77Z-2200-DA Brake Kit (1983-94, 10" Drum) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-97 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 985A36A Replace Rear Brake Shoes 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 2200 69 OASIS CODES: 301000, 702000, 702200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4374 Brake Shoe: Specifications Size ...................................................................................................................................................... ..................................... 254 X 63.5mm (10 X 2.5 in) Wheel Cylinder Bore Size ................................. .......................................................................................................................................... 19.0mm (0.75 in) Lining Thickness Primary ...................................................................................................... ................................................................... 4.80mm (0.189 in) Lining Thickness Secondary ............. .......................................................................................................................................................... 6.2mm (0.245 in) Lining Length Primary ............................................................................................. ................................................................................ 214.9mm (8.46 in) Lining Length Secondary ...... .............................................................................................................................................................. ........ 243.8mm (9.6 in) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4375 Brake Shoe: Testing and Inspection WARNING: Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining done on brake linings or pads should be done using proper exhaust-ventilated equipment. NOTE: Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake and Clutch Service Vacuum 091-00001 or Rotunda Brake Parts Washer 065-00016 or an equivalent. INSPECTION 1. Inspect rear brake shoes and linings (2200) for excessive lining wear or shoe damage. If lining is damaged or worn within 0.79mm (1/32 inch) of the rivet heads on riveted linings, it must be replaced. Replace any rear brake shoe and lining that has been contaminated with oil, grease or brake fluid. Replace rear brake shoe and lining in axle sets only. Never replace just one rear brake shoe and lining of a brake assembly. Replace both primary and secondary shoes. Prior to replacement of lining, brake drum diameter should be checked to determine that brake drum diameter is within specification. If braking surface diameter exceeds specification, the brake drum must be replaced. 2. Check condition of rear brake shoes and linings, retracting spring, hold-down springs, and brake drum for signs of overheating. If rear brake shoe and lining metal parts have a slight blue coloring, indicating overheating, retracting and hold-down springs should be replaced. Overheated springs lose their tension and could allow new rear brake shoe and lining to drag and wear prematurely, if not replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 4376 Brake Shoe: Adjustments The brake drums (1126) are automatically adjusted while driving the vehicle in reverse and sharply applying the brakes and then driving forward. It may be necessary to do this several times to obtain the proper rear brake adjustment. Manual brake adjustment is required only after the rear brake shoes and linings (2200) have been relined or replaced, or if adjuster has malfunctioned. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation Brake Shoe: Service and Repair Installation 1. Clean the ledge pads on the brake backing plate (2211). 2. Apply a light coating of disc brake caliper slide grease D7AZ-19590-A (ESA-M1C172-A) or equivalent at the points where the brake shoes touch the brake backing plate. 3. Before installing the rear rear brake shoes and linings, assemble the parking brake lever on the secondary shoe, secure with the spring washer and parking brake lever pin retainer. 4. Position the brake shoes on the brake backing plate, and install the brake shoe hold down spring pins (2069), brake shoe hold down springs (2068), and brake shoe hold down spring cups (2066) using Hold Down Spring Tool T73T-2300-A. Install the primary brake shoe parking brake lever link, parking brake link spring, and washer. Connect the parking brake rear cable and conduit to the parking brake lever. 5. Install the brake shoe anchor pin guide plate, if equipped. Place the cable anchor over the anchor pin with the crimped side toward the brake backing plate. 6. Install the primary shoe-to-anchor (short) spring using a brake spring removal/installation tool. 7. Install the cable guide on the secondary shoe web with the flanged holes fitted into the hole in the secondary shoe web. Thread the brake shoe adjusting lever cable around the cable guide groove. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4379 NOTE: Make sure the brake shoe adjusting lever cable is positioned in this groove, and not between the guide and the shoe web. 8. Install the secondary shoe-to-anchor (long) spring. NOTE: Make sure the cable end is not cocked or binding on the anchor pin when installed. All parts should be flat on the anchor pin. 9. Remove the brake cylinder clamp. CAUTION: Install the brake adjuster screw in the same location from which it was removed. Interchanging the brake adjuster screws from one side of the vehicle to the other will cause the brake shoes to retract rather than expand each time the automatic adjusting mechanism is operated. NOTE: To prevent incorrect installation, the socket end of each adjusting screw is stamped with R or L to indicate their installation on the right or left side of the vehicle. The adjusting pivot nuts can be distinguished by the number of lines machined around the body of the nut. Two lines indicate a right-hand nut; one line indicates a left-hand nut. Another way to identify adjusters is to check thread pitch. The right side adjuster has right-hand threads while the left side adjuster has left-hand threads. The adjuster will also increase in length when the lever is operated if properly installed. 10. Apply Premium Long-Life Grease XG-1-C or -K (ESA-M1C75-B) or equivalent to the threads and the socket end of the adjusting screw (part of brake adjuster screw. Turn the adjusting screw into the brake shoe adjusting screw nut (2047) to the end of the threads and then loosen it one-half turn. 11. Place the brake shoe adjusting screw socket on the brake adjuster screw and install the assembly between the shoe ends with the brake adjuster screw nearest the secondary rear brake shoe and lining. 12. Hook the cable hook into the hole in the brake shoe adjusting lever kit from the outboard plate side. The brake shoe adjusting lever kits are also stamped with an R or L to indicate their installation on the right or left hand brake assembly. 13. Place the hooked end of the brake shoe adjusting screw spring in the large hole in the primary shoe web. Connect the loop end of the brake shoe adjusting screw spring to the adjuster lever hole. 14. Pull the brake shoe adjusting lever kit, brake shoe adjusting lever cable and brake shoe adjusting screw spring down toward the rear to engage the pivot hook in the large hole in the secondary shoe web. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4380 15. Check the action of the adjuster by pulling brake shoe adjusting lever cable toward secondary shoe, activating brake shoe adjusting lever kit. Brake shoe adjusting lever kit should snap in behind the next tooth of adjuster. Release brake shoe adjusting lever cable to return brake shoe adjusting lever kit to original position and the adjuster should turn one notch. NOTE: If pulling the brake shoe adjusting lever cable does not produce the action described, or if brake shoe adjusting lever kit action is sluggish instead of positive and sharp, check the position of the brake shoe adjusting lever kit on the adjusting screw toothed wheel. The brake shoe adjusting lever kit should contact the adjusting wheel one tooth above the center line of the brake adjuster screw. If the contact point is below this center line, the brake shoe adjusting lever kit will not lock on the teeth in the adjusting screw wheel, and the brake adjuster screw will not be turned as the brake shoe adjusting lever kit is actuated by the brake shoe adjusting lever cable. Service adjuster as needed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4381 Brake Shoe: Service and Repair Removal 1. Remove the wheel (1007) and brake drum (1126). 2. Inspect rear wheel cylinder (2261) for signs of leaks or presence of rust by removing the boots and inspecting interior surfaces. Water leaking into the rear wheel cylinder past the boots will cause rust to form and may cause the rear wheel cylinder to seize. NOTE: If the boots are not removed, brake fluid leakage past the cups may go undetected because the boots may seal the fluid in the rear wheel cylinder. If leaks are found, the rear wheel cylinder must be repaired or replaced. 3. If no leaks are found, install Brake Cylinder Clamp D81L-1103-B or equivalent over the ends of the rear wheel cylinder as shown. 4. Contract the shoes as follows: a. Disengage the adjusting lever part of brake shoe adjusting lever kit (2A176) from the adjusting screw part of brake adjuster screw (2041) by pulling backward on the brake shoe adjusting lever cable (2A178). b. Shorten the length of the adjuster by screwing the threaded rod in. This is done by moving the outward side of the adjusting screw upward until the pivot nut is backed off as far as it will go. NOTE: Note the position of each spring, they must be re-assembled in the same position. 5. Pull the brake shoe adjusting lever kit, brake shoe adjusting lever cable and brake shoe adjusting screw spring (2049) down and toward the rear to unhook the pivot hook from the large hole in the secondary shoe web. Do not pry the pivot hook out of the hole. 6. Remove the brake shoe adjusting screw spring and brake shoe adjusting lever kit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4382 7. Remove the secondary shoe-to-anchor spring using a suitable brake spring removal/installation tool. Using the same tool, remove the primary shoe-to-anchor spring and unhook the cable anchor. Remove the brake shoe anchor pin guide plate (2028) (if equipped). 8. Remove the cable guide from the secondary shoe. 9. Remove the brake shoe retracting springs (2296) using Hold Down Spring Tool T73T-2300-A; remove the rear brake shoes and linings (2200), adjusting screw, pivot nut, and brake shoe adjusting screw socket (2048). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4383 10. Remove the primary brake shoe parking brake lever link (2A642) and parking brake link spring (2A601). Disconnect the parking brake rear cable and conduit (2A635) from the parking brake lever. Retainer Clip And Spring Washer 11. Remove the brake secondary shoe, then remove the retainer clip spring washer and remove the parking brake lever. Rear Brake Assembly ITEM PART NUMBER DESCRIPTION 1. 2069 Brake Shoe Hold Down Spring Pin 2. 2027 Anchor Pin 3. 2028 Brake Shoe Anchor Pin Guide Plate 4. 2A637 Parking Brake Lever 5. 2296 Brake Shoe Retracting Spring 7. 2200 Rear Brake Shoe and Lining 8. 2106 Washer 9. 2106 Parking Brake Lever Pin Retainer 10. 2A179 Cable Guide Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 4384 11. 2068 Brake Shoe Hold Down Spring 12. 2A642 Primary Brake Shoe Parking Brake Lever Link 13. 2A601 Parking Brake Link Spring 14. 2A787 Parking Brake Spring Retainer 15. 2A176 Brake Shoe Adjusting Lever Kit 16. 2048 Brake Shoe Adjusting Screw Socket 17. 2041 Brake Adjuster Screw 18. 2047 Brake Shoe Adjusting Screw Nut 19. 2049 Brake Shoe Adjusting Screw Spring 20. 2A178 Brake Shoe Adjusting Lever Cable 21. 2211 Brake Backing Plate Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications The following torque specifications are for clean, dirt-free and paint-free dry bolt and nut threads. Backing Plate to Axle Housing 25-35 ft.lb Wheel Cylinder to Backing Plate 9-13 ft.lb Brake Line to Wheel Cylinder 22-30 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4388 Wheel Cylinder: Diagrams Item Part Number Description 1. - Boot 2. 2196 Wheel Cylinder Piston 3. - Piston Cup 4. 2261 Rear Wheel Cylinder 5. 2208 Wheel Cylinder Bleeder Screw 6. 2204 Wheel Cylinder Piston Cup Spring Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 4389 Wheel Cylinder: Testing and Inspection WARNING: Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining done on brake linings or pads should be done using proper exhaust-ventilated equipment. NOTE: Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake and Clutch Service Vacuum 091-00001 or Rotunda Brake Parts Washer 065-00016 or an equivalent. INSPECTION 1. Rear wheel cylinders should not be disassembled unless they are leaking. Pull back each rear wheel cylinder dust boot and inspect for leakage. 2. Excessive brake fluid at this point indicates leakage past the piston cups and a need for rear wheel cylinder (2261) overhaul. A slight amount of fluid is nearly always present and acts as a lubricant for the pistons. If evidence of leakage is noted, the rear wheel cylinder should be disassembled, inspected and overhauled. 3. Inspect the rear wheel cylinder bore for scratches and pitting. If the rear wheel cylinder is pitted or has deep scratches, the rear wheel cylinder must be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal Wheel Cylinder Mounting Rear Wheel Cylinder 1. Raise vehicle on hoist and position suitable safety stands under vehicle. Remove wheel (1007). 2. Remove the wheel, brake drum (1126), and rear brake shoes and linings (2201). Remove the primary brake shoe parking brake lever links (2A642). 3. Disconnect the brake line from the rear wheel cylinder (2261). Connect a length of hose to the line and submerge end of hose in a can containing a small amount of brake fluid to prevent air from entering the system. 4. Remove the rear wheel cylinder retaining bolts and lockwashers, and then remove the rear wheel cylinder from the brake backing plate (2211). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 4392 Wheel Cylinder: Service and Repair Rebuild NOTE: For additional information see Fundamentals and Basics. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 4393 Wheel Cylinder: Service and Repair Installation 1. Apply Silicone Rubber D6AZ-19562-AA or equivalent to wheel cylinder mounting area to seal backing plate mounting area. 2. Place the rear wheel cylinder on the brake backing plate and install the retaining bolts and lockwashers. 3. Connect the brake line to the rear wheel cylinder. 4. Install the brake shoes and the connecting links (if equipped). Install the brake drum and adjust the brakes. 5. Install the wheel and tire assembly. 6. Perform system brake bleeding procedures. CAUTION: Check pedal operation before moving the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Description and Operation Brake Bleeding: Description and Operation WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the lines and cause spongy pedal action. This requires the bleeding of the hydraulic system after it has been properly connected to be sure all air is expelled from the brake cylinders and lines. The hydraulic system can be bled manually or with pressure bleeding equipment such as Rotunda(r) brake bleeder 104-00064 or equivalent. Bleed one brake cylinder at a time. Start the bleeding at the right rear brake wheel cylinder and then the left rear wheel brake cylinder. Then proceed to bleed the front brakes, starting with the right front brake and finish bleeding on the left front brake. Keep the brake master cylinder reservoir filled with the specified Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA (ESA-M6C25-A) or equivalent. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the master cylinder reservoirs filled with the specified brake fluid. Never reuse the fluid that has been drained from the hydraulic system. NOTE: Bleed the primary and secondary hydraulic brake systems separately. Master Cylinder Reservoir 1. On the brake master cylinder reservoir, loosen the master cylinder-to-hydraulic line fittings. 2. Wrap a shop cloth around the tubing below the fitting to absorb escaping brake fluid. 3. Push the brake pedal down slowly to the floor of the cab. This will force air trapped in the brake master cylinder reservoir to escape at the fitting. 4. Hold the brake pedal down and tighten the fitting. Release the brake pedal. NOTE: Do not release the brake pedal until the fitting is tightened or air will re-enter the brake master cylinder reservoir. 5. Repeat this procedure until air ceases to escape at the fitting. Wheel Cylinder Bleeding 6. Place a box wrench on the bleeder fitting on the rear anti-lock brake system valve. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly around the bleeder fitting. a. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. b. Slowly press the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. c. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 7. Place a box wrench on the right brake wheel cylinder. Attach a rubber drain tube to the bleeder fitting making sure the end of the tube fits snugly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4400 around the bleeder fitting. 8. Submerge the free end of the tube in a container partially filled with clean brake fluid. Loosen the bleeder fitting approximately three-quarters of a turn. 9. Slowly push the brake pedal all the way down. Close the bleeder fitting, and return the brake pedal to the fully-released position. Repeat this operation until air bubbles no longer appear at the submerged end of the bleeder tube. 10. When the fluid is completely free of air bubbles, close the bleeder fitting and remove the bleeder tube. 11. Repeat this procedure at the left brake wheel cylinder on the opposite side. Refill the brake master cylinder reservoir after each wheel cylinder is bled. 12. Bleed the front brakes starting with the right front brake and then the left front brake as described in Steps 7-11 of this procedure. 13. When the bleeding operation is complete, fill the brake master cylinder to the maximum level line of the brake master cylinder reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4401 Brake Bleeding: Service and Repair Pressure Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with running water for 15 minutes, get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Be sure the bleeder tank contains enough specified brake fluid (Ford Heavy Duty Brake Fluid C6AZ-19542-AA or BA [ESA-M6C25-A] or equivalent), to complete the bleeding operation. Charge the tank with approximately 69-206 kPa (10-30 psi) of air pressure. Never exceed 345 kPa (50 psi) of pressure. Never re-use brake fluid that has been drained from the hydraulic system. NOTE: Bleed the longest line first. 1. Clean all dirt from the brake master cylinder filler cap. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. 2. Remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. Install the pressure bleeder adapter tool, Rotunda Brake Bleeder model 104-00064 or equivalent to the brake master cylinder, and attach the bleeder tank hose to the fitting on the adapter. 3. Place a 3/8-inch box wrench on the bleeder fitting on the right rear brake wheel cylinder. Attach a bleeder tube snugly around the bleeder fitting. 4. open the valve on the bleeder tank to admit pressurized brake fluid to the master cylinder reservoir. 5. Submerge the free end of the tube on the wheel cylinder in a partially filled container of clean brake fluid. Loosen the bleeder fitting. 6. When air bubbles no longer appear in the fluid at the submerged end of the bleeder tube, close the bleeder fitting and remove the tube. Move on to the left rear, the right front, and finally left front. 7. When the bleeding operation is completed, close the bleeder tank valve and remove the tank hose from the adapter fitting. 8. Remove the pressure bleeder adapter tool. Fill the brake master cylinder reservoirs to the maximum level line. Install the brake master cylinder filler cap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4402 Brake Bleeding: Service and Repair Priming Brake System NOTE: When a brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the brake master cylinder using the following procedure: 1. Use a tubing wrench to remove the front brake tube (2264) and the brake master cylinder outlet rear tube from the brake master cylinder. 2. Install short brake tubes in the brake master cylinder and position them so that they curve into the brake master cylinder reservoir (2K478), and the ends of the tubes are submerged in brake fluid. 3. Fill the brake master cylinder reservoir with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brakes until clear, bubble-free fluid flows from both brake tubes. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. 5. Remove the short brake tubes and reinstall the front brake tube and brake master cylinder outlet rear tube on the brake master cylinder. 6. Bleed each brake tube at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal (2455) 10 times and then hold firm pressure on the brake pedal. b. On the brake master cylinder, loosen the rearmost brake tube fitting with a tubing wrench until a stream of brake fluid comes out. Have an assistant maintain pressure on the brake pedal until the brake tube fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tube fitting. Refill the brake master cylinder reservoir as necessary. d. Repeat this bleeding operation at the front brake tube fitting. 7. If any of the brake tubes, disc brake calipers, or rear wheel cylinders have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the brake master cylinder is primed and bled. 8. To gravity bleed the brake system: a. Fill the brake master cylinder with new Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. b. Loosen both of the rear bleeder screws and leave them open until clear brake fluid flows. Be sure to check the brake master cylinder reservoir fluid level often and do not let it run dry. c. Tighten the wheel cylinder bleeder screws to 7-9 Nm (62-79 in- lb). Tighten rear caliper bleed screws to 17-24 Nm (13-17 ft-lb). d. One at a time, loosen the front caliper bleeder screws. Leave the bleeder screws open until clear fluid flows. Check the fluid level often in the brake master cylinder reservoir and do not let it run dry. e. Tighten the front caliper bleeder screws to 17-24 Nm (13-17 ft-lb). 9. After the brake system has been primed, bleed the brake system at each wheel. NOTE: Keep the brake master cylinder reservoir filled with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Never use brake fluid that has been drained from the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 4403 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: The anti-lock brake system must be bled in two steps. 1. The brake master cylinder and Hydraulic Control Unit must be bled using Anti-lock Brake Adapter T90P-50-ALA and Jumper T93T-50-ALA. If this procedure is not followed, air will be trapped in the HCU which eventually leads to a spongy brake pedal. ANTILOCK BRAKE ADAPTER CONTROLS Item Part Number Description 1. T90P-50-ALA Anti-Lock Brake Adapter (Part of T90P-50-ALA) 2. -- Bleed/Harness Selector (Part of T90P-50-ALA) 3. -- Green "Motor On" Lamp (Part of T90-50-ALA) 4. -- Red "Motor Off" Lamp (Part of T90P-50-ALA) 5. -- Valve Button (Part of T90P-50-ALA) 6. -- Abort Button (Part of T90P-50-ALA) 7. -- Motor Start Button (Part of T90P-50-ALA) 2. To bleed the brake master cylinder and HCU, disconnect the 40-pin plug from the Electronic Control Unit and install the anti-lock brake adapter to the wire harness 40-pin plug. a. Place the bleed/harness selector in bleed position. b. Turn the ignition switch (11572) ON. At this point the red OFF indicator on the adapter should turn on. c. Push the motor button on the adapter down. This starts the pump motor. The red OFF indicator turns off and the green ON indicator turns on. The pump motor will run for 60 seconds once the motor button is pushed (you do not need to hold the button down). If the pump motor is to be turned off for any reason before this 60 seconds has elapsed, push the abort button and the pump motor will turn off. d. After the first 20 seconds have passed, push and hold the valve button for 20 seconds. This bleeds any trapped air from the brake master cylinder and HCU. e. The pump continues to run for an additional 20 seconds after the valve button is released. 3. Bleed the brake lines in the following order: ^ Right rear ^ Left front ^ Left rear ^ Right front Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Caliper Type Pin-Slider Bolt-On Anchor Caliper Part Number (RH) F57A-2B120-DC Caliper Part Number (LH) F57A-2B121-DC No. Of Piston(s) Per Brake Two Caliper Piston Diameter 1.81 in Effective Radius 4.21 in Caliper Bracket Bolts 74-96 ft.lb Caliper Pin Bolts 38-48 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4407 Brake Caliper: Diagrams ITEM PART NUMBER DESCRIPTION 1. 2C150 Caliper Pins 2. 2208 Wheel Cylinder Bleeder Screw 3. 2B121 Front Disc Brake Caliper 4. 2B115 Piston Seal 5. 2196 Caliper Piston 6. 18K005 Dust Boot 7. 2019 Inner Shoe and Lining (RH) 7. 2C046 Inner Shoe and Lining (LH) 8. 2B164 Brake Shoe Hold Down Spring 9. 2018 outer Shoe and Lining (RH) 9. 2C088 outer Shoe and Lining (LH) 10. - Torque Buttons (Part of 2B121) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Page 4408 Brake Caliper: Description and Operation OPERATION All vehicles are equipped with front disc brake calipers (2B120). Front disc brake calipers use pin rail-type caliper assemblies with a cast iron rotor integral with the front hub assembly. The front disc brake caliper (2B120) consists of a pin slider caliper housing, inner and outer shoe and lining assemblies, and a wheel cylinder piston (2196). The front disc brake caliper slides on two pins which also attach the front disc brake caliper to the front wheel spindle (3105). The caliper housing contains a wheel cylinder piston. The wheel cylinder piston has a molded rubber dust boot on its outer end that is pressed into a cylinder bore groove to prevent cylinder contamination. There is also a rectangular section rubber piston seal located in the cylinder bore providing sealing between the cylinder and wheel cylinder piston. This seal also causes the wheel cylinder piston to retract once the brakes are released. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Front Caliper Assembly Item Part Number Description 1 2B115 Piston Seal 2 2196 Caliper Piston 3 2207 Dust Boot 4 2B120 Disc Brake Caliper 5 2208 Bleeder Screw 6 -- Caliper Bore (Part of 2B120) 7 -- Seal Groove (Part of 2B120) DISASSEMBLY 1. Remove the front disc brake caliper from the vehicle. Place a block of wood over the wheel cylinder piston before applying air pressure to prevent damage to the wheel cylinder piston. WARNING: Use care because the wheel cylinder piston can develop considerable force from pressure build-up. 2. Apply air pressure to the fluid port in the front disc brake caliper with a rubber-tipped nozzle TOOL 7000-DE to remove the wheel cylinder piston. NOTE: If the wheel cylinder piston is seized and cannot be forced from the front disc brake caliper, tap lightly around the wheel cylinder piston while applying air pressure. 3. Remove the dust boot from the front disc brake caliper. 4. Remove the rubber piston seal from the wheel bearing (1240) and discard it. ASSEMBLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4411 1. Apply a film of clean brake fluid to the new caliper piston seal, and install it in the cylinder bore. Be sure the seal does not become twisted but is firmly seated in the groove. 2. Coat the wheel cylinder piston wheel cylinder piston with brake fluid. Spread the dust boot over the wheel cylinder piston wheel cylinder piston seating the dust boot in the caliper piston groove. 3. Install the wheel cylinder piston wheel cylinder piston into the cylinder bore. 4. The dust boot flange should set squarely in the outer groove of the caliper bore when the wheel cylinder piston is completely installed. 5. Install the front disc brake caliper over the rotor. Tools Required: ^ Air Nozzle Tool-7000-DE ^ Rubber Tip for Air Nozzle Tool-7000-DD Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4412 Brake Caliper: Service and Repair Inspection INSTALLATION 1. The wheel cylinder piston must be "bottomed out" when installing new shoe and lining assemblies. Be sure that enough fluid has been removed from brake master cylinder (see Step 1 of Removal) to prevent fluid overflow. Bottom out the wheel cylinder piston with an eight-inch C-clamp using a worn-out inner shoe or a block of wood to push against the wheel cylinder piston. 2. Place a new brake shoe hold down spring on the lower end of the inner shoe. Be sure the tabs on the front disc brake caliper are positioned properly and the front disc brake caliper is fully seated. 3. Position the inner shoe and front disc brake caliper in the shoe abutment of the front wheel spindle with the anti-rattle clip tab against the shoe abutment and the loop-type spring away from the front disc brake rotor. 4. Compress the front disc brake caliper and slide the upper end of the shoe in position. WARNING: Outer shoe torque buttons must be solidly seated in caliper holes or temporary loss of brakes may occur. 5. Install the outer shoe, making sure the torque buttons on the shoe are seated solidly in the matching holes in the front disc brake caliper. 6. Make sure the mounting surfaces are free of dirt and corrosion, and lubricate the caliper grooves with Disc Brake Caliper Grease D7AZ-19590-A (ESA-M1C172-A) or equivalent, then position the front disc brake caliper on the front wheel spindle. NOTE: Be sure to install the caliper pins so the retention tabs will be in contact with the front wheel spindle, not the front disc brake caliper. When the upper pin is properly positioned, the retention tabs will be at the top, against the front wheel spindle. When the lower pin is properly positioned, the retention tabs will be at the bottom, also in contact with the front wheel spindle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4413 Caliper Slide Pin Positioning 7. From the caliper outboard side, position the pin between the front disc brake caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face. NOTE: During the installation procedure, do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens, it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle face. Caliper Pin Installation 8. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the front wheel spindle face. Repeat procedure for the lower pin. 9. If removed, install the front brake hose to the front disc brake caliper. 10. If the front brake hose was removed, perform brake bleeding procedures. 11. Install the wheel and tire assembly. Tighten lugnuts to 114-141 Nm (85-105 ft lb). 12. Lower vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation then recheck brake fluid level in brake master cylinder. Fill as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4414 Brake Caliper: Service and Repair Removal NOTE: If the front disc brake calipers are to be removed for service other than to replace brake shoes, fluid removal from the brake master cylinder (2140) may not be required. Removing some fluid will prevent fluid from overflowing from the brake master cylinder when the wheel cylinder piston are pressed into their bores. CAUTION: System contamination may result if anything other than a clean device is used to remove fluid from brake master cylinder. REMOVAL 1. Use a clean siphon or suction hose to remove a portion of the fluid from the brake master cylinder. Discard the removed fluid. 2. Raise the vehicle and install safety stands. Remove a front wheel and tire assembly. CAUTIONS: ^ Do not position C-clamp on the brake shoe hold down spring. Also, do not compress wheel cylinder piston further than is required to disengage torque buttons from front disc brake caliper. Damage to the brake shoe hold down spring will result. Replace shoe if brake shoe hold down spring is bent or damaged. ^ Do not attempt to "bottom" the wheel cylinder piston in the bore at this time. Use an old, worn out brake shoe or block of wood and the C-clamp to bottom the wheel cylinder piston once the front disc brake caliper is removed from front disc brake rotor, and the shoes are removed from the front disc brake caliper. 3. Use an eight-inch C-clamp to move the wheel cylinder piston back into its bore as follows: a. Place the head of the C-clamp against the front disc brake caliper, and the screw end of the C-clamp against the outer shoe below the spring clip. b. Tighten the clamp until the torque buttons just clear the caliper (about 3mm [1/8 inch]). Remove the C-clamp. c. Do not use a screwdriver or similar tool to pry the wheel cylinder piston away from the front disc brake rotor. 4. Clean excess dirt from area around pin tabs. 5. Using Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the caliper pin from the front disc brake caliper as follows: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4415 Caliper Pin Removal a. Position the notched end of the tool against the caliper pin (retention tab half), at a 45° angle from the pin retention tabs. b. Tap the tool with the hammer to compress the retention tabs. c. As the retention tabs are compressed, move the tool to gain a straight approach to the pin, and continue tapping to drive the pin through the caliper/spindle groove. 6. Remove the front disc brake caliper from the rotor. If the front disc brake caliper is to be removed for service, disconnect the brake hose from the front disc brake caliper. If not, secure the front disc brake caliper with wire. NOTE: do not let the front disc brake caliper hang with its weight on the front brake hose (2078). Inner Brake Pad 7. Compress the brake shoe hold down spring and remove the inner shoe from the front disc brake caliper. Outer Pad Removal 8. To remove the outer shoe from the front disc brake caliper, press each ear of the shoe away from the front disc brake caliper, slide the torque Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 4416 buttons out of the retention notches and slide the shoe off. CAUTION: Never attempt to bottom out the wheel cylinder piston with the outer shoe installed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. Brake Fluid DOT 3 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the antilock brake system and illuminate the antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 4424 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The fluid level indicator is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. CONSTRUCTION It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Testing and Inspection Brake Hose/Line: Testing and Inspection Replace a flexible brake hose if it shows signs of softening, cracking or other damage. When installing a new brake hose, position the hose to avoid contact with other vehicle parts. The wet appearance of the outer cover of rubber brake hoses is called "sweating". This is a normal condition for neoprene rayon braid hose. The "sweating" condition is not evidence of a brake fluid leak and will not result in a loss of pressure in the system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring A Tube (Flaring-Bar Type) Brake Hose/Line: Service and Repair Flaring A Tube (Flaring-Bar Type) CAUTION: Copper tubing should not be used in the hydraulic system. Use only SAE J526 or J527 steel tubing, or equivalent. NOTES: - If a section of the brake tube is damaged, replace the entire section with steel brake tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending to fit the frame or rear axle forms. - Double flare brake tubing as described below should provide good leak-proof connections. Always clean the inside of a new brake tube with clean isopropyl alcohol. 1. Cut off and straighten the required length of tube. A tubing cutter tool will simplify making a clean and square cut. 2. Square off the ends of the tube with a file, and chamfer the end of the tube to be flared. 3. Insert the tube through appropriate ribbed hole in the bar assembly until the end of the tube sticks out about as far as the thickness of the adapter above the bar, or even with the bar, depending on the tool used. 4. Fit the adapter onto the tube and slide the bar into the yoke. Lock the bar in position with the tube beneath the yoke screw. 5. Form the single flare by tightening the yoke screw securely. 6. Release the screw and remove the adapter. 7. Form the double flare by tightening the yoke screw again, with the second adapter fitted, depending on the tool used. 8. Release the screw bar and flared tube. 9. Inspect the flare for cracks or poor flare form and repeat the process if the flare is not correct. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring A Tube (Flaring-Bar Type) > Page 4430 Brake Hose/Line: Service and Repair Flaring A Tube (Split-Die Type) CAUTION: Copper tubing should not be used in the hydraulic system. Use only SAE J526 or J527 steel tubing, or equivalent. NOTES: - If a section of the brake tube is damaged, replace the entire section with steel brake tubing of the same type, size, shape, and length. Be careful not to kink or crack the tubing when bending to fit the frame or rear axle forms. - Double flare brake tubing as described below should provide good leak-proof connections. Always clean the inside of a new brake tube with clean isopropyl alcohol. 1. Cut off and straighten the required length of tube. NOTE: A tubing cutter tool will simplify making a clean and square cut. 2. Square off the ends of the tube with a file, and chamfer the end of the tube to be flared. 3. Select the split die for the tube to be used and insert the die into the tapered hole in the body. 4. Push the tube through the die until the tube is even with the face of the die. Lock the tube in this position by tightening the wing nut securely. 5. The punches are marked Op. 1 and Op. 2. Slide the first operation punch into the hole in the center of the body and tighten the screw securely to form the single flare. 6. Release the screw and replace the first operation punch with the second operation punch and tighten the screw to form the double flare. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring A Tube (Flaring-Bar Type) > Page 4431 7. Release the screw, wing nut, punch, and dies. 8. Remove the tube and inspect the flare for cracks or poor flare form. If the flare is not correct, cut it off and repeat the process. NOTE: The finished flare must be square with the tube, free of cracks and have a smooth mating surface to make sure the connection is leak-proof. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams 4WABS Hydraulic Unit Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4435 4WABS Hydraulic Control Unit: Description and Operation 4WABS Hydraulic Schematic PURPOSE The Hydraulic Control Unit (HCU) is used to control brake hydraulic pressure to prevent wheel lock-up during braking. OPERATION The HCU is located in the front of the engine compartment on the left frame rail. It consists of a valve body assembly, a pump and a motor assembly. During normal braking, fluid from the master cylinder enters the HCU through two inlet ports located at the top of the HCU. The fluid then passes through three normally open inlet valves, one to each wheel in the front and one line to the rear wheels. If the Electronic Control Unit (ECU) senses that a wheel is about to lock, the ECU pulses the appropriate inlet valve which closes that valve. This prevents any more fluid from entering the affected brake. The ECU then looks at that wheel again. If it is still decelerating, the ECU pulses the normally closed outlet valve which decreases the pressure trapped in the line. NOTE: The valve body, the pump and the motor are not serviceable separately. 4WABS Hydraulic Control Unit Item Part Number Description 1. 2B112 Tube 2. 2234 Tube 3. 2C215 Hydraulic Control Unit (HCU) 4. W611633 Screw 5. 2263 Tube 6. 2264 Tube 7. 2B523 Tube 8. N606703 Bolt 9. N801107 U-Nut Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4436 4WABS Hydraulic Control Unit: Service and Repair 4WABS Brake Control System Item Part Number Description 1. 2C018 Electronic Control Unit (ECU) 5. 2C215 Hydraulic Control Unit (HCU) 7. 2234 Tube Assembly 11. 2263 Tube Assembly 12. N802768 Clip 13. 2264 Tube Assembly 14. 2B557 Hose Assembly 15. 2078 Hose Assembly 19. 2C008 Tube Assembly REMOVAL 1. Disconnect positive battery cable. 2. Disconnect 8-pin connector attaching Hydraulic Control Unit (HCU) to wire harness, and disconnect 4-pin connector attaching pump motor to harness. 3. Remove two tubes from inlet ports and three tubes from outlet ports of HCU. Plug each port to prevent brake fluid from spilling on paint and wiring. 4. Remove three nuts retaining HCU assembly to mounting bracket and remove assembly from vehicle. CAUTION: The HCU is not interchangeable with other units. Be sure to replace with correct part. INSTALLATION 1. Insert HCU assembly into mounting bracket. Install three retaining nuts and tighten to 16-24 Nm (12-18 ft lb). 2. Connect three tubes to outlet ports on side of HCU and two tubes to inlet ports on front of HCU. Tighten tube fittings to 14-24 Nm (10-18 ft lb). 3 Connect 8-pin connector and 4-pin connector to harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > 4WABS Hydraulic Control Unit <--> [Hydraulic Control Assembly - Antilock Brakes] > Component Information > Diagrams > Page 4437 NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Connect positive battery cable. 5. Perform brake bleeding procedure. Check for fluid leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > NHTSA96V024001 > Feb > 96 > Recall 96V024001: Brake Master Cylinder Stud Cracking Brake Master Cylinder: Recalls Recall 96V024001: Brake Master Cylinder Stud Cracking THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION. IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER COULD THEN SEPARATE FROM THE VACUUM BOOSTER, WHEN THE BRAKES ARE APPLIED, PREVENTING THE SERVICE BRAKES FROM ACTIVATING INCREASING THE RISK OF A VEHICLE ACCIDENT. DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY. SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1991 FORD TRUCK EXPLORER 1991 FORD TRUCK RANGER 1992 FORD TRUCK EXPLORER 1992 FORD TRUCK RANGER 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK RANGER 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Recalls for Brake Master Cylinder: > NHTSA96V024000 > Feb > 95 > Recall 96V024000: Master Cylinder Stud Cracking Brake Master Cylinder: Recalls Recall 96V024000: Master Cylinder Stud Cracking THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION. IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER COULD THEN SEPARATE FROM THE VACUUM BOOSTER, WHEN THE BRAKES ARE APPLIED, PREVENTING THE SERVICE BRAKES FROM ACTIVATING, INCREASING THE RISK OF A VEHICLE ACCIDENT. DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY. SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673 OR MAZDA AT 1-800-222-5500. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1991 FORD TRUCK EXPLORER 1991 FORD TRUCK RANGER 1991 MAZDA TRUCK NAVAJO 1992 FORD TRUCK EXPLORER 1992 FORD TRUCK RANGER 1992 MAZDA TRUCK NAVAJO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK RANGER 1993 MAZDA TRUCK NAVAJO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK RANGER 1994 MAZDA TRUCK B2300 1994 MAZDA TRUCK B3000 1994 MAZDA TRUCK B4000 1994 MAZDA TRUCK NAVAJO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA96V024001 > Feb > 96 > Recall 96V024001: Brake Master Cylinder Stud Cracking Brake Master Cylinder: All Technical Service Bulletins Recall 96V024001: Brake Master Cylinder Stud Cracking THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION. IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER COULD THEN SEPARATE FROM THE VACUUM BOOSTER, WHEN THE BRAKES ARE APPLIED, PREVENTING THE SERVICE BRAKES FROM ACTIVATING INCREASING THE RISK OF A VEHICLE ACCIDENT. DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY. SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1991 FORD TRUCK EXPLORER 1991 FORD TRUCK RANGER 1992 FORD TRUCK EXPLORER 1992 FORD TRUCK RANGER 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK RANGER 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Master Cylinder: > NHTSA96V024000 > Feb > 95 > Recall 96V024000: Master Cylinder Stud Cracking Brake Master Cylinder: All Technical Service Bulletins Recall 96V024000: Master Cylinder Stud Cracking THE STUDS WHICH ATTACH THE BRAKE MASTER CYLINDER TO THE POWER BRAKE VACUUM BOOSTER ASSEMBLY CAN DEVELOP STRESS CORROSION CRACKING AFTER BEING OPERATED FOR AN EXTENDED PERIOD OF TIME IN THE SOUTHERN CALIFORNIA LOCATION. IF A CRACK OCCURS, IT COULD RESULT IN ONE OR BOTH STUDS FRACTURING. THE MASTER CYLINDER COULD THEN SEPARATE FROM THE VACUUM BOOSTER, WHEN THE BRAKES ARE APPLIED, PREVENTING THE SERVICE BRAKES FROM ACTIVATING, INCREASING THE RISK OF A VEHICLE ACCIDENT. DEALERS WILL REPLACE THE POWER BRAKE VACUUM BOOSTER ASSEMBLY. SYSTEM: BRAKES; POWER ASSIST; PRIMARY; BOOSTER. VEHICLE DESCRIPTION: MULTI-PURPOSE VEHICLES AND LIGHT DUTY TRUCKS ORIGINALLY SOLD OR CURRENTLY REGISTERED IN THE SOUTHERN CALIFORNIA COUNTIES OF LOS ANGELES, ORANGE, SAN BERNADINO, SAN DIEGO, RIVERSIDE, VENTURA, SANTA BARBARA, SAN LUIS OBISPO, IMPERIAL, AND KERN. NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME, SHOULD CONTACT FORD AT 1-800-392-3673 OR MAZDA AT 1-800-222-5500. ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1991 FORD TRUCK EXPLORER 1991 FORD TRUCK RANGER 1991 MAZDA TRUCK NAVAJO 1992 FORD TRUCK EXPLORER 1992 FORD TRUCK RANGER 1992 MAZDA TRUCK NAVAJO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK RANGER 1993 MAZDA TRUCK NAVAJO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK RANGER 1994 MAZDA TRUCK B2300 1994 MAZDA TRUCK B3000 1994 MAZDA TRUCK B4000 1994 MAZDA TRUCK NAVAJO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir Brake Master Cylinder: Description and Operation Brake Fluid Reservoir Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the antilock brake system and illuminate the antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 4461 Brake Master Cylinder: Description and Operation Master Cylinder, ABS PURPOSE The brake master cylinder (2140) takes mechanical input from the power brake booster and changes it to hydraulic pressure. OPERATION The brake master cylinder contains two hydraulic pistons. One piston controls the rear brakes and the other the front brakes. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Fluid Reservoir > Page 4462 Brake Master Cylinder: Description and Operation Master Cylinder, Brakes Master Cylinder Item Part Number Description 1. - Compensating Ports (Part of 2140) 2. 2162 Brake Master Cylinder Filler Cap 3. - Float Magnet Assembly (Part of 2K478) 4. - Primary Piston (Part of 2140) 5. - Bore End Seal (Part of 2140) 6. - Spring (Part of 2140) 7. - Seal (Part of 2140) 8. - Secondary Piston (Part of 2140) 9. 2140 Brake Master Cylinder 10. 2K478 Brake Master Cylinder Reservoir The dual master cylinder performs in the following manner: ^ Rear wheel brakes - are connected to the secondary outlet port and are actuated by the secondary piston assembly. ^ Front wheel brakes - are connected to the primary outlet port (nearest the dash panel) and are actuated by the primary piston assembly. NOTE: Both primary and secondary pistons function together. CONSTRUCTION The dual master cylinder contains a plastic "see through" fluid reservoir with a Fluid Level Indicator (FLI) and primary and secondary hydraulic pistons and an integral proportioning valve. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Brake Master Cylinder: Initial Inspection and Diagnostic Overview Normal/Abnormal Conditions NOTE: The following conditions are considered normal and are not indications that the brake master cylinder is in need of service. NORMAL CONDITIONS - Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will fall during brake application and rise during release. The net fluid level, i.e., after brake application and release, will remain unchanged. - Condition 2: A trace of brake fluid existing on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. - Condition 3: Fluid level will decrease with pad wear. ABNORMAL CONDITIONS - Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. NOTE: Prior to performing any diagnosis, make certain the brake system warning lamp is functional. - The diagnostic techniques and service procedures are referenced in the Brake Master Cylinder Diagnostic Pinpoint charts Inspection 1. Clean all master cylinder parts in clean isopropyl alcohol, or use the Rotunda(r) Brake Parts Washer 065-00016 or equivalent and inspect the parts for wear or damage. Replace them if required. When a master cylinder repair kit is used, follow the instructions in the kit and install all of the parts provided. 2. Make sure all ports and vents in the brake master cylinder are open and free of foreign matter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4465 Brake Master Cylinder: Component Tests and General Diagnostics Brake Master Cylinder Reservoir Checking and Filling Brake fluid level in the brake master cylinder reservoir should be between 4mm (0.16 inch) below the MAX line on the side of the brake master cylinder reservoir and the MAX line. If brake fluid is low, the red brake indicator will illuminate. To add brake fluid, clean and remove anti-lock reservoir cap and pour clean brake fluid into the top of the brake master cylinder reservoir. Fill to specification mentioned above. Use Heavy-Duty Brake Fluid C6AZ-19542-AA (ESA-M6C25-A) or Dot 3 equivalent. If brake fluid has to be added often, check all hydraulic connections for leaks. Non-Pressure Leaks The only part of the brake system that could have a brake fluid loss that did not appear when the system is under pressure is the brake master cylinder reservoir area. Brake fluid loss could be caused by a missing or poorly fitted brake master cylinder filler cap, from a punctured or otherwise damaged brake master cylinder reservoir, by a missing or damaged brake master cylinder filler cap gasket, or at the sealing grommets between the brake master cylinder and the brake master cylinder reservoir. The brake master cylinder reservoir grommets are not separately serviceable and must be replaced with a new brake master cylinder reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal and Installation REMOVAL 1. Disconnect the brake warning lamp indicator wire from the plastic reservoir fluid level indicator socket. Drain the brake fluid from the brake master cylinder. 2. Using a large screwdriver, pry between the brake master cylinder reservoir and the brake master cylinder and remove the brake master cylinder reservoir. Master Cylinder Reservoir CAUTION: Whenever the brake master cylinder is replaced, the brake tube grommets (2k409) must also be replaced or leakage may occur causing brake system failure. INSTALLATION 1. Lubricate the two brake tube grommets included in Service Kit 2K478 with Heavy Duty Brake Fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or an equivalent DOT 3 fluid. Insert the brake tube grommets into the brake master cylinder. 2. Press the brake master cylinder reservoir into the brake tube grommets with the fluid level indicator socket facing inboard. The brake master cylinder reservoir should snap in place indicating that it is secure. 3. Connect the brake warning lamp indicator wire to the fluid level indicator socket. 4. Fill the brake master cylinder reservoir with Heavy Duty Brake Fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent. Disassembly and Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 4468 Item Part Number Description 1. 2K478 Brake Master Cylinder Reservoir 2. 2140 Brake Master Cylinder 3. - Spring (Part of 2140) 4. - Spring Seat (Part of 2140) 5. - Piston Cup (Part of 2140) 6. - Secondary Piston (Part of 2140) 7. - Snap Ring (Part of 2140) 8. - Primary Piston (Part of 2140) 9. - Spring Retainer (Part of 2140) DISASSEMBLY 1. Clean the outside of the brake master cylinder and remove the brake master cylinder filler cap and diaphragm. Drain and discard any brake fluid that remains in the brake master cylinder. 2. Depress the primary piston and remove snap ring from retaining groove at the rear of the master cylinder bore. Primary Piston Assembly 3. Remove the rear washer, seal and guide, along with the primary piston assembly from the bore. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 4469 Secondary Piston Assembly 4. Remove the secondary piston assembly by directing compressed air into the outlet port at the blind end of the bore while plugging the other port. Inspect for seal damage or twisting. Discard assembly. NOTE: Do not attempt to hone a master cylinder bore if damage is found. If bore is found to be in good condition, check for availability of service repair kits. If none are available, brake master cylinder must be replaced. 5. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage. ASSEMBLY 1. Clean the master cylinder body with clean isopropyl alcohol to remove any contamination. 2. Dip the repair kit piston assemblies in clean brake fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent to lubricate seals. 3. Carefully insert the complete secondary piston assembly in the master cylinder bore. 4. Assemble the washer, rear seal and guide over the primary piston. Be careful not to scratch or damage the exposed section of the primary piston. Install into cylinder bore. 5. Depress the primary piston and install the snap ring in the cylinder bore groove. 6. Install the cap and diaphragm on the brake master cylinder reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 4470 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Removal REMOVAL 1. Disconnect the brake warning lamp indicator wire from the plastic reservoir low fluid level warning switch socket. 2. With the engine (6007) turned off, push the brake pedal down to expel vacuum from the power brake booster (2005). 3. Disconnect the brake master cylinder connector tube (2A040) from the brake master cylinder. 4. Remove the wrap-around clip and attaching nut from the booster master cylinder mounting stud. Brake Master Cylinder 5. Remove the brake booster-to-master cylinder retaining nuts. Remove the brake master cylinder from the power brake booster. Installation Power Brake Booster Push Rod Adjustment Gauge NOTE: Before installing the brake master cylinder, check the distance from the outer end of the booster assembly push rod to the front face of the power brake booster. Turn the push rod adjustment screw in or out as required to obtain the specified length (until adjustment screw just touches gauge block). Fabricate gauge block using dimension shown. INSTALLATION 1. Position the brake master cylinder over the booster push rod and onto the two studs on the power brake booster. Install the attaching nuts and tighten to 18-33 Nm (13-25 ft lb). 2. Loosely connect the brake master cylinder connector tube to the brake master cylinder. 3. Position the wrap-around clip on the mounting stud. Install and tighten the attaching nut. 4. Tighten the tube nuts to 14-20 Nm (10-15 ft lb). 5. Connect fluid level indicator switch. 6. Bleed the brake master cylinder. See: Brake Bleeding Then fill the brake master cylinder reservoir of the brake master cylinder with Heavy Duty Brake Fluid C6AZ-19542-AA or -BA (ESA-M6C25-A) or equivalent Dot 3 brake fluid to the fluid fill line. 7. Install the gasket and brake master cylinder filler cap (2162). 8. Perform brake bleeding procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications The following torque specifications are for clean, dirt-free and paint-free dry bolt and nut threads. Backing Plate to Axle Housing 25-35 ft.lb Wheel Cylinder to Backing Plate 9-13 ft.lb Brake Line to Wheel Cylinder 22-30 ft.lb Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4474 Wheel Cylinder: Diagrams Item Part Number Description 1. - Boot 2. 2196 Wheel Cylinder Piston 3. - Piston Cup 4. 2261 Rear Wheel Cylinder 5. 2208 Wheel Cylinder Bleeder Screw 6. 2204 Wheel Cylinder Piston Cup Spring Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 4475 Wheel Cylinder: Testing and Inspection WARNING: Brake assembly dust and dirt should not be removed by either blowing off with an air gun or vacuuming with a standard industrial vacuum cleaner because a health hazard from breathing in asbestos dust may develop. Also, any machining done on brake linings or pads should be done using proper exhaust-ventilated equipment. NOTE: Removal of dust and dirt from brake assemblies should be done by using the Rotunda Brake and Clutch Service Vacuum 091-00001 or Rotunda Brake Parts Washer 065-00016 or an equivalent. INSPECTION 1. Rear wheel cylinders should not be disassembled unless they are leaking. Pull back each rear wheel cylinder dust boot and inspect for leakage. 2. Excessive brake fluid at this point indicates leakage past the piston cups and a need for rear wheel cylinder (2261) overhaul. A slight amount of fluid is nearly always present and acts as a lubricant for the pistons. If evidence of leakage is noted, the rear wheel cylinder should be disassembled, inspected and overhauled. 3. Inspect the rear wheel cylinder bore for scratches and pitting. If the rear wheel cylinder is pitted or has deep scratches, the rear wheel cylinder must be replaced. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal Wheel Cylinder: Service and Repair Removal Wheel Cylinder Mounting Rear Wheel Cylinder 1. Raise vehicle on hoist and position suitable safety stands under vehicle. Remove wheel (1007). 2. Remove the wheel, brake drum (1126), and rear brake shoes and linings (2201). Remove the primary brake shoe parking brake lever links (2A642). 3. Disconnect the brake line from the rear wheel cylinder (2261). Connect a length of hose to the line and submerge end of hose in a can containing a small amount of brake fluid to prevent air from entering the system. 4. Remove the rear wheel cylinder retaining bolts and lockwashers, and then remove the rear wheel cylinder from the brake backing plate (2211). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 4478 Wheel Cylinder: Service and Repair Rebuild NOTE: For additional information see Fundamentals and Basics. Rear Wheel Cylinder DISASSEMBLY 1. Remove the rubber boots from the ends of the brake cylinder. 2. Remove the pistons, cups and piston cup spring. 3. Remove the wheel cylinder bleeder screw. Ensure the bleeder screw is not plugged. ASSEMBLY 1. Coat all wheel cylinder parts with clean brake fluid or brake assembly lube. 2. Install the bleeder screw into the wheel cylinder. 3. Place the wheel cylinder piston cup spring, cups and pistons into the wheel cylinder. 4. Install a boot and wheel cylinder brake shoe link over each end of the wheel cylinder. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal > Page 4479 Wheel Cylinder: Service and Repair Installation 1. Apply Silicone Rubber D6AZ-19562-AA or equivalent to wheel cylinder mounting area to seal backing plate mounting area. 2. Place the rear wheel cylinder on the brake backing plate and install the retaining bolts and lockwashers. 3. Connect the brake line to the rear wheel cylinder. 4. Install the brake shoes and the connecting links (if equipped). Install the brake drum and adjust the brakes. 5. Install the wheel and tire assembly. 6. Perform system brake bleeding procedures. CAUTION: Check pedal operation before moving the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation Parking Brake Cable: Service and Repair Removal and Installation Front Cable Item Part Number Description 1. 2780 Parking Brake Control 2. N806497-S2 M8-1.25 x 25.7 Hex Bolt. Tighten to 16-24 Nm (12-18 ft lb). 3. 2853 Front Parking Brake Cable and Conduit 4. 2A620 Parking Brake Intermediate Cable 5. 2273 Grommet 6. 2A610 Bracket 7. N802621-S53B M12-1.75 Nut Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 4485 8. N605933-S2 M12-1.75 x 30 HexBolt. Tighten to 68-92 Nm (50-68 ft lb). 9. 2A530 Rear Guide Bracket 10. 2A709 Rear Parking Brake Cable Retainer 11. 2A826 Parking Brake Cable Retainer Clip 12. N611194-S2 Screw (6). Tighten to 6-8 Nm (53-71 in lb). 13. 377669-S8 Clip 14. N610959-S2 Screw. Tighten to 15-20 Nm (11-15 ft lb). 15. 2A635 Right Side Cable Assembly 16. 2A809 Left Side Cable Assembly 17. 2A602 Parking Brake Cable Equalizer A. - Assemble cable assembly into pivot hole in ratchet plate in this position. B. - After cable is assembled, rotate it to this position. C. - after all cables have been assembled, pull pin to adjust parking brake system. REMOVAL 1. While an assistant relieves tension on the system by pulling on the parking brake intermediate cable or front parking brake cable and conduit (2853) insert a 4mm (5/32-inch) steel pin or equivalent drill bit into the hole provided in the parking brake control (2780). See: Tension Release 2. Disconnect the parking brake intermediate cable or front parking brake cable and conduit from the LH parking brake rear cable and conduit (2A635). 3. To replace the parking brake intermediate cable vehicles, disconnect it from the front parking brake cable and conduit and remove it. 4. To replace the front parking brake cable and conduit, remove the cable anchor pin from the pivot hole in the control assembly ratchet pin. 5. Guide the front parking brake cable and conduit from the parking brake control and disconnect it from the frame mounting bracket. Remove cable-to-frame attaching bolt, if bolt is present, and slide front parking brake cable and conduit from vehicle. INSTALLATION 1. Feed the front parking brake cable and conduit through the hole in the front frame mounting bracket. Push the retainer through the hole so the fingers expand over the hole. 2. Route the front parking brake cable and conduit around the control assembly pulley and insert the cable anchor pin in the pivot hole in the ratchet assembly. 3. If removed, install cable-to-frame attaching bolt. 4. For intermediate cable installation, feed cable through holes in center frame bracket. 5. Attach cable to front parking brake cable and conduit and to left rear parking brake rear cable and conduit. Rear REMOVAL 1. While an assistant relieves tension on the system by pulling on the parking brake intermediate cable or front parking brake cable and conduit (2853), insert a 4mm (5/32-inch) steel pin or equivalent size drill bit into the hole provided in the parking brake control (2780). See: Tension Release 2. Raise the vehicle and remove the hub cap, wheel and tire, and remove the brake drum (1126). 3. Disconnect the left parking brake rear cable and conduit (2A635) from the front parking brake cable and conduit. 4. 5. Disconnect right parking brake rear cable and conduit from the parking brake cable equalizer and from the rear guide bracket. 6. At the wheel side of the brake backing plate (2211), compress the retainer fingers with a 9/16-inch flare nut wrench and remove the parking brake Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 4486 rear cable and conduit through the hole in the brake backing plate. 7. Lift the parking brake rear cable and conduit out of the slot in the parking brake lever (attached to the brake secondary shoe). Remove the parking brake rear cable and conduit through the backing plate hole. INSTALLATION 1. Route the parking brake rear cable and conduit through the hole in the brake backing plate. 2. Insert the cable anchor behind the slot in the parking brake lever. Make sure the parking brake rear cable and conduit is securely engaged in the parking brake lever so the rear parking brake cable retainer (2A709) is holding the parking brake rear cable and conduit in the parking brake lever. 3. Push the parking brake cable retainer clip (2A826) through the hole in the brake backing plate so the retainer fingers engage the brake backing plate. Rear Brake Drum 4. Route the parking brake rear cable and conduit as shown in the illustrations. 5. Insert the front of the right parking brake rear cable and conduit into the rear guide bracket until the prongs expand. 6. Connect the left rear parking brake cable to the front parking brake cable and conduit. 7. Remove the lock pin from the parking brake control to apply cable tension. 8. Adjust rear brakes. 9. Install the brake drum, wheel, and hub cap. 10. Apply and release the parking brake control several times. Rotate both wheels to be sure that the parking brakes are not dragging. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 4487 Parking Brake Cable: Service and Repair Tension Release NOTE: If any component in the parking brake system requires servicing, the cable tension must be released. After servicing is completed, the front parking brake cable and conduits (2853) and parking brake rear cable and conduits (2A635) are connected to the parking brake cable bracket (2530) and tension is reset. Refer to the following procedures for releasing and resetting cable tension. 1. Place the parking brake control (2780) in the "released" position. Parking Brake Control 2. While an assistant relieves tension on the system by pulling on the parking brake intermediate cable, insert a 4mm (5/32-inch), steel pin or equivalent drill bit into the hole provided in the parking brake control. NOTE: Be careful not to damage the plastic coating on the cable strand. Remove the parking brake rear cable and conduits (2A635) from the parking brake cable bracket (2530). 3. Another method, which releases tension on the parking brake rear cable and conduits only, is to pull rearward on the parking brake rear cable and conduit about 25-50mm (1.0-2.0 inches) and place a clamp on the parking brake rear cable and conduit behind the rear frame crossmember (5035). 4. Another method which can be used is to remove the bolts attaching the parking brake control to the floor pan, and pull the parking brake control upward and forward to rotate the spring-loaded ratchet wheel as far as possible. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 4488 Parking Brake Cable: Service and Repair Tension Resetting NOTE: Parking brake control spring tension is lost when the coil spring unwinds and disengages from the tab on the wheel. This can occur when the cables break, when servicing the system without inserting the lock pin or when the lock pin is removed before the cables are connected. CAUTION Do not service the parking brake system without inserting the lock pin in the control assembly. Do not remove the lock pin from the control with the cables disconnected. 1. Remove the parking brake control. 2. Engage the coil spring on the tab on the wheel in the parking brake control. 3. Place the control handle in the released position to unlock the self-adjusting pawl. 4. Slip a spare front parking brake cable and conduit (2853) around the pulley and insert the cable anchor pin into the pivot hole in the ratchet plate assembly Cable Assembly Inserted Into Pivot Hole Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal and Installation > Page 4489 5. With the front parking brake cable and conduit on the floor, step on the front parking brake cable and conduit or clamp the end of the front parking brake cable and conduit in a vise. 6. Pull on the assembly, holding the mounting bracket tightly against the body of the control, until cable tension rotates the cable track assembly so the lock pin can be fully seated through the plate. Parking Brake Control 7. Insert the lock pin so the assembly is in the "cable released" position. 8. Install the parking brake control. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Control: > 00-1-2 > Jan > 00 > Parking Brake Control Assembly - Concerns Parking Brake Control: Customer Interest Parking Brake Control Assembly - Concerns Article No. 00-1-2 01/10/00 PARKING BRAKE - PARKING BRAKE CONTROL ASSEMBLY CONCERNS - BRONCO AND F-SERIES BUILT THROUGH 4/22/1994 AND EXPLORER/RANGER BUILT THROUGH 5/13/1994 FORD: 1992-1994 BRONCO, F-150-350 SERIES 1993-1994 EXPLORER, RANGER This TSB is being republished in its entirety to better define the diagnostic procedure. ISSUE ^ # 1) The parking brake control assembly may bind causing it not to engage, fully release, or return. ^ # 2) The parking brake pedal may go to the floor with little or no effort during application. This may occur because the adjustment pawl does not totally engage during rapid pedal application on occasion. ACTION Issue 1 Follow normal diagnostic procedures to confirm that other portions of the parking brake system are not causing system binding. If required, replace the parking brake control assembly with a new parking brake control assembly. Refer to the appropriate Service Manual, Section 06-05 for the proper procedure. Issue 2 The following repair action is only to be used after the Lock-in Wedge part (Explorer/Ranger F4TZ-2L780-C, Bronco/F-Series F4TZ-2L780-D) installation described in TSB 00-01-1 has been performed. If the previously installed lock-in wedge will not stay in place or the concern still exists after the wedge has been installed, replace the parking brake control assembly with a new parking brake control assembly. Refer to the Service Manual, Section 06-05 and the following supplemental text for the proper procedure. Be sure to depress the parking brake through 15 to 50 degrees of rotation by hand. NOTE A MINIMUM OF 15 DEGREES OF ROTATION IS REQUIRED TO BE SURE THE PARKING BRAKE SYSTEM IS TENSIONED AND THE PARKING PAWL WILL NOT JAM UP ON INITIAL FOOT APPLICATION. THE PARKING BRAKE PEDAL MAY JAM AT 15 DEGREES DURING HAND APPLY, BUT THE PARKING BRAKE SYSTEM WILL BE SUFFICIENTLY TENSIONED TO ELIMINATE INITIAL FOOT APPLY JAM UP CONDITION. DO NOT ATTEMPT TO PUSH THE PEDAL PAST THE JAM UP POSITION IF IT OCCURS. Pull the parking brake release and be sure the parking brake pedal has returned completely prior to initial foot apply. PART NUMBER PART NAME F4TZ-2L780-C Lock-In Wedge F4TZ-2L780-D Lock-In Wedge F4TZ-2780-A Parking Brake Control F4TZ-2780-B Parking Brake Control OTHER APPLICABLE ARTICLES: 00-01-1 SUPERSEDES: 98-5A-37 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Control: > 00-1-2 > Jan > 00 > Parking Brake Control Assembly - Concerns Parking Brake Control: All Technical Service Bulletins Parking Brake Control Assembly - Concerns Article No. 00-1-2 01/10/00 PARKING BRAKE - PARKING BRAKE CONTROL ASSEMBLY CONCERNS - BRONCO AND F-SERIES BUILT THROUGH 4/22/1994 AND EXPLORER/RANGER BUILT THROUGH 5/13/1994 FORD: 1992-1994 BRONCO, F-150-350 SERIES 1993-1994 EXPLORER, RANGER This TSB is being republished in its entirety to better define the diagnostic procedure. ISSUE ^ # 1) The parking brake control assembly may bind causing it not to engage, fully release, or return. ^ # 2) The parking brake pedal may go to the floor with little or no effort during application. This may occur because the adjustment pawl does not totally engage during rapid pedal application on occasion. ACTION Issue 1 Follow normal diagnostic procedures to confirm that other portions of the parking brake system are not causing system binding. If required, replace the parking brake control assembly with a new parking brake control assembly. Refer to the appropriate Service Manual, Section 06-05 for the proper procedure. Issue 2 The following repair action is only to be used after the Lock-in Wedge part (Explorer/Ranger F4TZ-2L780-C, Bronco/F-Series F4TZ-2L780-D) installation described in TSB 00-01-1 has been performed. If the previously installed lock-in wedge will not stay in place or the concern still exists after the wedge has been installed, replace the parking brake control assembly with a new parking brake control assembly. Refer to the Service Manual, Section 06-05 and the following supplemental text for the proper procedure. Be sure to depress the parking brake through 15 to 50 degrees of rotation by hand. NOTE A MINIMUM OF 15 DEGREES OF ROTATION IS REQUIRED TO BE SURE THE PARKING BRAKE SYSTEM IS TENSIONED AND THE PARKING PAWL WILL NOT JAM UP ON INITIAL FOOT APPLICATION. THE PARKING BRAKE PEDAL MAY JAM AT 15 DEGREES DURING HAND APPLY, BUT THE PARKING BRAKE SYSTEM WILL BE SUFFICIENTLY TENSIONED TO ELIMINATE INITIAL FOOT APPLY JAM UP CONDITION. DO NOT ATTEMPT TO PUSH THE PEDAL PAST THE JAM UP POSITION IF IT OCCURS. Pull the parking brake release and be sure the parking brake pedal has returned completely prior to initial foot apply. PART NUMBER PART NAME F4TZ-2L780-C Lock-In Wedge F4TZ-2L780-D Lock-In Wedge F4TZ-2780-A Parking Brake Control F4TZ-2780-B Parking Brake Control OTHER APPLICABLE ARTICLES: 00-01-1 SUPERSEDES: 98-5A-37 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Technical Service Bulletins > Page 4503 Parking Brake Control: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Cable Tension, Release Parking Brake Control: Service and Repair Cable Tension, Release NOTE: If any component in the parking brake system requires servicing, the cable tension must be released. After servicing is completed, the front parking brake cable and conduits (2853) and parking brake rear cable and conduits (2A635) are connected to the parking brake cable bracket (2530) and tension is reset. Refer to the following procedures for releasing and resetting cable tension. 1. Place the parking brake control (2780) in the "released" position. Parking Brake Control 2. While an assistant relieves tension on the system by pulling on the parking brake intermediate cable, insert a 4mm (5/32-inch), steel pin or equivalent drill bit into the hole provided in the parking brake control. NOTE: Be careful not to damage the plastic coating on the cable strand. Remove the parking brake rear cable and conduits (2A635) from the parking brake cable bracket (2530). 3. Another method, which releases tension on the parking brake rear cable and conduits only, is to pull rearward on the parking brake rear cable and conduit about 25-50mm (1.0-2.0 inches) and place a clamp on the parking brake rear cable and conduit behind the rear frame crossmember (5035). 4. Another method which can be used is to remove the bolts attaching the parking brake control to the floor pan, and pull the parking brake control upward and forward to rotate the spring-loaded ratchet wheel as far as possible. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Cable Tension, Release > Page 4506 Parking Brake Control: Service and Repair Control Assembly Spring Tension, Resetting NOTE: Parking brake control spring tension is lost when the coil spring unwinds and disengages from the tab on the wheel. This can occur when the cables break, when servicing the system without inserting the lock pin or when the lock pin is removed before the cables are connected. CAUTION Do not service the parking brake system without inserting the lock pin in the control assembly. Do not remove the lock pin from the control with the cables disconnected. 1. Remove the parking brake control. 2. Engage the coil spring on the tab on the wheel in the parking brake control. 3. Place the control handle in the released position to unlock the self-adjusting pawl. 4. Slip a spare front parking brake cable and conduit (2853) around the pulley and insert the cable anchor pin into the pivot hole in the ratchet plate assembly Cable Assembly Inserted Into Pivot Hole Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Cable Tension, Release > Page 4507 5. With the front parking brake cable and conduit on the floor, step on the front parking brake cable and conduit or clamp the end of the front parking brake cable and conduit in a vise. 6. Pull on the assembly, holding the mounting bracket tightly against the body of the control, until cable tension rotates the cable track assembly so the lock pin can be fully seated through the plate. Parking Brake Control 7. Insert the lock pin so the assembly is in the "cable released" position. 8. Install the parking brake control. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Service and Repair > Cable Tension, Release > Page 4508 Parking Brake Control: Service and Repair Removal and Installation REMOVAL 1. Remove the left side cowl trim panel. 2. Disconnect the parking brake indicator light switch connector from the control assembly connector. 3. Relieve tension on the system by having an assistant pull on the parking brake intermediate cable (2A620) or front parking brake cable and conduit while you insert a 5/32-inch drill bit into the hole provided in the parking brake control. 4. Remove the cable anchor pin from the pivot hole in the control assembly ratchet plate. Guide the front parking brake cable and conduit from the parking brake control. NOTE: Do not remove the steel lock pin from the parking brake control until the cable is connected to the control assembly. Pin removal releases the tension in the ratchet wheel causing the spring to unwind and release tension. If the pin is prematurely removed, spring tension in the parking brake control must be reset. See: Control Assembly Spring Tension, Resetting 5. Remove the screw attaching the instrument panel to the parking brake control. 6. Remove bolts retaining the parking brake control to the left side cowl and remove the parking brake control from the vehicle. INSTALLATION 1. Route the front parking brake cable and conduit around the parking brake control and insert the cable anchor pin in the pivot hole provided in the ratchet plate. 2. Position the parking brake control and install the attaching bolts. Tighten bolts to 17-23 Nm (13-17 ft lb). 3. Install the screw attaching the instrument panel to the parking brake control. 4. Connect the parking brake indicator light switch indicator to the control assembly connector. 5. Carefully remove the lock pin (drill bit) from the parking brake control. NOTE: The system will automatically tension itself when the pin is removed. 6. Install the left side cowl trim panel. 7. Apply and release the parking brake several times to verify correct operation. Also, verify proper operation of the parking brake indicator light. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation Technical Service Bulletin # 94S91 Date: 941101 Recall - Parking Brake Lock In Wedge Installation 94S91 Certain 1992-1994 Bronco, F-150-350 Series Trucks and 1993-1994 Explorer/Ranger Vehicles Equipped with Manual Transmissions - Installation of a Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal Law requires dealers to complete any outstanding safety recall service before a new vehicle is sold and delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. District Contact Advise district office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Service Zone Manager or Dealer Assistance Center about all matters. Form 1863/64 Submit 1864 claims using DWE for all completed vehicles. You may use your original 1863 for your record file copy. Warranty and Policy Manual See Section 6.3, pages 5 through 8, of your Warranty and Policy Manual for claims preparation. For dealers on ACESII Pilot, see Section 5 and 6 of ACESII Manual. Refunds See Section 6.3, page 9 or your Warranty and Policy Manual. Use Customer Concern Code X99 for safety recalls. For dealers on ACESII Pilot, see section 3-55. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4517 Attachment II - Labor and Parts Information Installation of a Parking Brake Lock-in Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F150-350 Series Trucks and Certain 1993-1994 Model Year Explorer/Ranger Vehicles. Labor Allowances For Dealers NOT On ACESII Pilot OPERATION DESCRIPTION LABOR TIME LABOR OPERATION Inspect vehicle for previous wedge installation 0.2 Hrs. Insert in Box "A" on Form 1864 or Cam-In Brake design Install Parking Brake Lock-In Wedge (includes 0.3 Hrs. Insert in Box "B" on Form 1864 Inspection, Function Test and Wedge Removal as required) Install Parking Brake Wedge and Adjust Brakes 0.6 Hrs. Insert in Box "C" on Form 1864 (includes inspection) Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Labor Allowances For Dealers On ACESII Pilot Submit using DWE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Inspect vehicle for previous wedge installation or 0.2 Hrs. 94S91A Cam-In Brake design Install Parking Brake Lock-In Wedge (Includes 0.3 hrs. 94S91B Inspection) Install Parking Brake Wedge and Adjust Brakes 0.6 Hrs. 94S91C (Includes Inspection, Function Test and Wedge Removal as required) Administrative Allowance 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION DEALER PRICE F4TZ-2L780-C Wedge - Explorer/Ranger (Large size, Black) $2.87 F4TZ-2L780-D Wedge - Bronco/F-Series (Small size, White) $2.87 Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Instructions Installation Of A Parking Brake Lock-In Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and certain 1993-1994 Model Year Explorer/Ranger Trucks equipped with manual transmissions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4518 Technical Instructions NOTE: It is imperative that you fully read the following procedures and complete all the steps in the procedure. This procedure includes some inspection and verification steps in addition to those included in prior TSB's on this subject. Inspection 1. Park the vehicle in a flat area. Turn the ignition "OFF". 2. If the vehicle is a 1992 or 1993 F-Series or Bronco, inspect the release rod and spring for proper position. The release rod must be fully inserted into the slot in the bracket and the spring must be located behind the slot in the bracket. Refer to Figure 1. 3. Inspect parking brake control assembly to determine what action is required. a. If the parking brake control assembly is of the new cam-in post design. it does not require installation of the wedge. See Figure 2. DO NOT PROCEED. File form 1864 for inspection only and release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4519 b. If the wedge has been previously installed as illustrated in Figure 3. ^ If wedge is properly installed, go to PARKING BRAKE FUNCTIONAL TEST. ^ If wedge is not installed as shown in figures, remove wedge as outlined in Steps 1 through 4 of PARKING BRAKE ADJUSTMENT PROCEDURE, then continue with WEDGE INSTALLATION. c. If the wedge is not present or the vehicle is not equipped with the cam-in post design parking brake control assembly, proceed with WEDGE INSTALLATION. NOTE: Previously installed wedges may be translucent rather than white (Bronco/F-Series) or Black (Ranger/Explorer). Lock-In Wedge Installation 1. Apply and release parking brake at least six (6) times allowing pedal to return each item without any interference. This will "neutralize" the parking brake cable system and allow for proper evaluation of the system once the wedge is installed. 2. Apply foot pressure to the pedal so that the pedal rotates (about 2-1/2" to 3") from the "RELEASED" position. See Figure 4. WARNING BE CAREFUL NOT TO ACCIDENTALLY RELEASE THE PARKING BRAKE SPRING LOADED RELEASE ARM DURING THE INSTALLATION PROCEDURE BY PULLING ANYWHERE ON THIS RELEASE LEVER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4520 3. Check that the pawl is fully seated in the bottom of a ratchet tooth. See Figure 5. If not, re-cycle pedal as outlined in Step 2. 4. After full engagement of the pawl and ratchet is assured, apply foot pressure to the pedal to fully rotate the pedal to the full "APPLIED" position (this allows you more room to make installation easier). See Figure 6. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4521 5. Grab the tab of the wedge (Figure 7) with needle nose pliers and position it so that the small teeth on the concave surface are pointing up. NOTE: The Explorer/Ranger and Bronco/F-Series wedges are not the same. The wedge for the Explorer/Ranger is black, and the wedge for the Bronco/F-Series is white. See Figure 8 for identification of the wedges. 6. Using needle nose pliers, insert the wedge between the pawl and the ratchet with the flange of the wedge behind the pawl and ratchet. See Figure 9. 7. Check that the wedge is properly located between the pawl and the ratchet and that the flange is behind the pawl and ratchet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4522 8. Use a small hammer and punch to apply light force to the back end (or drive area) of the wedge. See Figure 10. 9. Use sufficient force to ensure adequate seating of the wedge into the ratchet teeth. On Explorer/Ranger models, more force may be required to completely seat wedge. Check the wedge for proper alignment with the pawl after seating. See Figure 11. 10. After the wedge is properly seated, cycle the lever mechanism "APPLIED" and "RELEASED" a minimum of six (6) times, leaving the pedal in the full "APPLIED" position after the last application. 11. Recheck the wedge to be sure it is fully engaged in its proper position. NOTE: The parking brake light should be off when the parking brake is released. If the light is on with the parking brake released, check the wedge installation (Step 9). Parking Brake Functional Test NOTE: The installation of the lock-in wedge disables the self-adjusting feature of the parking brake control assembly. The following parking brake functional test must be performed to verify proper parking brake system adjustment. 1. Place vehicle on hoist with the transmission in neutral. a. Verify the parking brake is fully released. Check for brake drag by turning the rear wheels by hand. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4523 b. Check for a firm pedal feel while fully applying the parking brakes. 2. If vehicle experiences either brake drag or a "soft" pedal, go to PARKING BRAKE ADJUSTMENT PROCEDURE. Parking Brake Adjustment Procedure NOTE: Perform the following adjustment procedure only if directed here from the Parking Brake Functional Test or only perform Steps 1 thru 4 if wedge removal is required. To perform the parking brake adjustment procedure, the lock wedge must first be removed from the control assembly. Upon completion of the adjustment procedure, the wedge must be reinstalled. 1. To remove the wedge, apply pressure to the pedal until a full travel position is achieved. The pedal will be in a vertical position. 2. Use a pair of standard pliers or needle nose vice grips to grip the tab of the lock-in wedge. WARNING CARE MUST BE USED TO AVOID ACTIVATING THE RELEASE LEVER DURING WEDGE REMOVAL. 3. With a twisting motion, pull out the wedge. 4. Inspect the wedge for damage. If the tab is broken off, if it is missing teeth or if it is severely damaged in any other fashion, discard it. Obtain a new wedge for installation. 5. Release the parking brake. 6. With the vehicle still on a hoist, have an assistant rotate one rear wheel to check for drag while you pull on the appropriate cable until a slight drag is felt at the wheel. a. F-Series/Bronco - pull forward on corresponding rear cable at equalizer. b. Explorer/Ranger - pull forward on front cable. 7. At this point, push rearward on the cable a slight amount until the wheel spins freely. 8. Have the assistant rotate the opposite wheel and adjust the corresponding cable as outlined in steps 6 and 7. 9. Recheck the first wheel to verify correct parking brake adjustment. 10. Apply the parking brake and install wedge as outlined in steps 2-11 of LOCK-IN WEDGE INSTALLATION. 11. Perform PARKING BRAKE FUNCTIONAL TEST. Dealer Letter RECALL NUMBER 94S91 Date: Nov., 1994 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers AT PDC By: Now Date in Owner Letter: November, 1994 - phased mail To: All Ford Dealers Subject: Safety Recall 94S91 - Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger Vehicles equipped Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4524 with Manual Transmission - Installation of a Parking Brake Lock-in Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F150-350 Series Trucks equipped with manual transmissions and produced prior to the following dates: ASSEMBLY PLANT PRODUCTION DATE Norfolk Assembly 1/27/94 Michigan Truck 2/04/94 Ontario Truck 2/09/94 Kentucky Truck 2/16/94 Kansas City Assembly 4/22/94 All 1993-1994 Model Year Ranger/Explorer vehicles with manual transmission produced prior to 5/01/94. Reasons For Recall During rapid pedal application, the parking brake pedal, with little or no effort, may go to the floor and the parking brake may be ineffective in holding the vehicle stationary. Should this occur, the self-adjustment pawl may skip over one or more teeth on the ratchet. To correct this condition, a lock-in wedge will be installed in the parking brake assembly. This wedge locks out the self-adjustment mechanism and retains the adjustment pawl in mesh with the ratchet. WARNING DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY. ALWAYS SET THE PARKING BRAKE FULLY AND TURN OFF THE IGNITION WHEN LEAVING THE VEHICLE. NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter November, 1994 Serial Number: 12345678901234567 94S91 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4525 Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger vehicles. Safety Defect During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system may not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness. Repairs At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information. WARNING DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY. NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. How Long Will It Take? The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Truck? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built truck. Supplement Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Dealer Letter To: All Ford Dealers Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4526 Reference: Safety Recall Bulletin 94S91, dated October 25, 1994. Subject: Safety Recall 94S91 Supplement # 1 - Additional Units The purpose of this bulletin is to advise you that 1994 model year Rangers equipped with manual transmission built at Edison Assembly Plant from 5/1/94 through 5/13/94 and 1994 model year Rangers and Explorers equipped with manual transmission built at Louisville Assembly Plant from 5/1/94 through 5/12/94 have been added to the referenced recall. According to our records, the additional involved vehicle(s) shown on the enclosed listing have been delivered to your dealership. Notification Of Owners Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by first class mail. If the owner of any vehicle cannot be contacted or does not make an appointment to have the vehicle corrected, advise your FCSD Regional Office of the owner's name and address so that we can handle further notification. Recall Procedures Refer to the Recall 94S91 Bulletin, dated October 25, 1994 for technical instructions, parts information and reporting procedures. Questions? Claims Information 1-800-423-8851 Technical Assistance 1-800-826-4694 Other Recall Questions 1-800-825-5621 Owner Letter June, 1995 Serial Number: 12345678901234567 94S91 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-35- Series pickup trucks and chassis cabs and 1993-1994 Model Year Explorers and Rangers. Safety Defect During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system nay not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness. Repairs At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information. Warning Do not park the vehicle in Neutral. Use First (1) gear and set the parking brake fully. (Note: When the transfer case is in the N (neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral)). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in first (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. How Long Will It Take? The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4527 Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Truck? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for safety and satisfaction with your Ford-built truck. Supplement Parking Brake Lock-in Wedge Supplement - July, 1995 Identifies Additional Vehicles Involved Dealer Letter Attachments not Applicable Customer Notification Letter not Applicable Dealer Letter To: All Ford Dealers Reference: Safety Recall Bulletin 94S91, dated October 25, 1994 Subject: Safety Recall 94S91 - Supplement # 2 - Additional Units Affected Vehicles The purpose of this bulletin is to advise you that 1992 model year F-Series 150-350 trucks equipped with manual transmissions built at Twin Cities Assembly Plant from 8/20/91 through 6/12/92 have been added to the referenced recall. According to our records, the additional involved vehicle(s) shown on the enclosed listing have been delivered to your dealership. Notification of Owners Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by first class mail. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise regional office if: ^ an owner cannot be contacted ^ an owner does not make a service date. Recall Procedures Refer to the Recall 94S91 Bulletin, dated October 25, 1994 for technical instructions, parts information and reporting procedures. Questions? Claims Information 1-800-423-8851 Other Recall Questions 1-800-825-5621 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > NHTSA94V169000 > Aug > 94 > Recall 94V169000: Parking Brake Defect Parking Brake Pedal: Recalls Recall 94V169000: Parking Brake Defect THE PARKING BRAKE CONTROL SELF-ADJUST PAWL DOES NOT LINE UP PROPERLY WITH THE SELF-ADJUST RACHET CAUSING THE PAWL TO SLIP OVER ONE OR MORE TEETH IN THE RACHET. WHEN THE ABOVE OCCURS, IT CAN RESULT IN PARKING BRAKE SYSTEM IN EFFECTIVENESS. THE PARKING BRAKE WILL NOT HOLD THE VEHICLE, CAUSING THE VEHICLE TO ROLL FREELY, IF THE TRANSMISSION IS NOT LEFT IN GEAR. A WEDGE WILL BE INSTALLED WHICH WILL SERVE TO LOCK THE PARKING BRAKE SELF-ADJUST MECHANISM PAWL INTO ENGAGEMENT WITH THE RACHET. ALSO, OWNERS WILL BE ADVISED TO RELEASE AND RE-APPLY THE PARKING BRAKE WHENEVER TOOTH SKIP OCCURS AND WILL BE REMINDED TO ALWAYS TURN OFF THE ENGINE AND LEAVE THE VEHICLE IN GEAR WHEN THE VEHICLE IS PARKED. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND MULTI-PURPOSE VEHICLES WITH MANUAL TRANSMISSIONS. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1993 FORD TRUCK BRONCO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK RANGER 1993 MAZDA TRUCK NAVAJO 1994 FORD TRUCK BRONCO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK F150 1994 FORD TRUCK F250 1994 FORD TRUCK F350 1994 FORD TRUCK RANGER 1994 MAZDA TRUCK B SERIES 1994 MAZDA TRUCK NAVAJO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > Recalls for Parking Brake Pedal: > NHTSA94V169001 > Aug > 94 > Recall 94V169001: Parking Brake Defect Parking Brake Pedal: Recalls Recall 94V169001: Parking Brake Defect THE PARKING BRAKE CONTROL SELF-ADJUST PAWL DOES NOT LINE UP PROPERLY WITH THE SELF-ADJUST RACHET CAUSING THE PAWL TO SLIP OVER ONE OR MORE TEETH IN THE RACHET. WHEN THE ABOVE OCCURS, IT CAN RESULT IN PARKING BRAKE SYSTEM IN EFFECTIVENESS. THE PARKING BRAKE WILL NOT HOLD THE VEHICLE, CAUSING THE VEHICLE TO ROLL FREELY, IF THE TRANSMISSION IS NOT LEFT IN GEAR. A WEDGE WILL BE INSTALLED WHICH WILL SERVE TO LOCK THE PARKING BRAKE SELF-ADJUST MECHANISM PAWL INTO ENGAGEMENT WITH THE RACHET. ALSO, OWNERS WILL BE ADVISED TO RELEASE AND RE-APPLY THE PARKING BRAKE WHENEVER TOOTH SKIP OCCURS AND WILL BE REMINDED TO ALWAYS TURN OFF THE ENGINE AND LEAVE THE VEHICLE IN GEAR WHEN THE VEHICLE IS PARKED. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND MULTI-PURPOSE VEHICLES WITH MANUAL TRANSMISSIONS. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1993 FORD TRUCK BRONCO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK RANGER 1994 FORD TRUCK BRONCO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK F150 1994 FORD TRUCK F250 1994 FORD TRUCK F350 1994 FORD TRUCK RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation Technical Service Bulletin # 94S91 Date: 941101 Recall - Parking Brake Lock In Wedge Installation 94S91 Certain 1992-1994 Bronco, F-150-350 Series Trucks and 1993-1994 Explorer/Ranger Vehicles Equipped with Manual Transmissions - Installation of a Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. Please Note Correct all vehicles in stock before delivery. Federal Law requires dealers to complete any outstanding safety recall service before a new vehicle is sold and delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,000 per vehicle. Promptly Correct Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. District Contact Advise district office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. FCSD Contact Talk with your FCSD Service Zone Manager or Dealer Assistance Center about all matters. Form 1863/64 Submit 1864 claims using DWE for all completed vehicles. You may use your original 1863 for your record file copy. Warranty and Policy Manual See Section 6.3, pages 5 through 8, of your Warranty and Policy Manual for claims preparation. For dealers on ACESII Pilot, see Section 5 and 6 of ACESII Manual. Refunds See Section 6.3, page 9 or your Warranty and Policy Manual. Use Customer Concern Code X99 for safety recalls. For dealers on ACESII Pilot, see section 3-55. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4541 Attachment II - Labor and Parts Information Installation of a Parking Brake Lock-in Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F150-350 Series Trucks and Certain 1993-1994 Model Year Explorer/Ranger Vehicles. Labor Allowances For Dealers NOT On ACESII Pilot OPERATION DESCRIPTION LABOR TIME LABOR OPERATION Inspect vehicle for previous wedge installation 0.2 Hrs. Insert in Box "A" on Form 1864 or Cam-In Brake design Install Parking Brake Lock-In Wedge (includes 0.3 Hrs. Insert in Box "B" on Form 1864 Inspection, Function Test and Wedge Removal as required) Install Parking Brake Wedge and Adjust Brakes 0.6 Hrs. Insert in Box "C" on Form 1864 (includes inspection) Administrative Allowance 0.1 Hrs. NOTE: Add Administrative Allowance to the total repair time. Labor Allowances For Dealers On ACESII Pilot Submit using DWE OPERATION DESCRIPTION LABOR TIME LABOR OPERATION/CODE Inspect vehicle for previous wedge installation or 0.2 Hrs. 94S91A Cam-In Brake design Install Parking Brake Lock-In Wedge (Includes 0.3 hrs. 94S91B Inspection) Install Parking Brake Wedge and Adjust Brakes 0.6 Hrs. 94S91C (Includes Inspection, Function Test and Wedge Removal as required) Administrative Allowance 0.1 Hrs. Misc. Expense Code "ADMIN" Parts Requirements Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION DEALER PRICE F4TZ-2L780-C Wedge - Explorer/Ranger (Large size, Black) $2.87 F4TZ-2L780-D Wedge - Bronco/F-Series (Small size, White) $2.87 Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book Attachment III - Technical Instructions Installation Of A Parking Brake Lock-In Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and certain 1993-1994 Model Year Explorer/Ranger Trucks equipped with manual transmissions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4542 Technical Instructions NOTE: It is imperative that you fully read the following procedures and complete all the steps in the procedure. This procedure includes some inspection and verification steps in addition to those included in prior TSB's on this subject. Inspection 1. Park the vehicle in a flat area. Turn the ignition "OFF". 2. If the vehicle is a 1992 or 1993 F-Series or Bronco, inspect the release rod and spring for proper position. The release rod must be fully inserted into the slot in the bracket and the spring must be located behind the slot in the bracket. Refer to Figure 1. 3. Inspect parking brake control assembly to determine what action is required. a. If the parking brake control assembly is of the new cam-in post design. it does not require installation of the wedge. See Figure 2. DO NOT PROCEED. File form 1864 for inspection only and release the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4543 b. If the wedge has been previously installed as illustrated in Figure 3. ^ If wedge is properly installed, go to PARKING BRAKE FUNCTIONAL TEST. ^ If wedge is not installed as shown in figures, remove wedge as outlined in Steps 1 through 4 of PARKING BRAKE ADJUSTMENT PROCEDURE, then continue with WEDGE INSTALLATION. c. If the wedge is not present or the vehicle is not equipped with the cam-in post design parking brake control assembly, proceed with WEDGE INSTALLATION. NOTE: Previously installed wedges may be translucent rather than white (Bronco/F-Series) or Black (Ranger/Explorer). Lock-In Wedge Installation 1. Apply and release parking brake at least six (6) times allowing pedal to return each item without any interference. This will "neutralize" the parking brake cable system and allow for proper evaluation of the system once the wedge is installed. 2. Apply foot pressure to the pedal so that the pedal rotates (about 2-1/2" to 3") from the "RELEASED" position. See Figure 4. WARNING BE CAREFUL NOT TO ACCIDENTALLY RELEASE THE PARKING BRAKE SPRING LOADED RELEASE ARM DURING THE INSTALLATION PROCEDURE BY PULLING ANYWHERE ON THIS RELEASE LEVER. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4544 3. Check that the pawl is fully seated in the bottom of a ratchet tooth. See Figure 5. If not, re-cycle pedal as outlined in Step 2. 4. After full engagement of the pawl and ratchet is assured, apply foot pressure to the pedal to fully rotate the pedal to the full "APPLIED" position (this allows you more room to make installation easier). See Figure 6. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4545 5. Grab the tab of the wedge (Figure 7) with needle nose pliers and position it so that the small teeth on the concave surface are pointing up. NOTE: The Explorer/Ranger and Bronco/F-Series wedges are not the same. The wedge for the Explorer/Ranger is black, and the wedge for the Bronco/F-Series is white. See Figure 8 for identification of the wedges. 6. Using needle nose pliers, insert the wedge between the pawl and the ratchet with the flange of the wedge behind the pawl and ratchet. See Figure 9. 7. Check that the wedge is properly located between the pawl and the ratchet and that the flange is behind the pawl and ratchet. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4546 8. Use a small hammer and punch to apply light force to the back end (or drive area) of the wedge. See Figure 10. 9. Use sufficient force to ensure adequate seating of the wedge into the ratchet teeth. On Explorer/Ranger models, more force may be required to completely seat wedge. Check the wedge for proper alignment with the pawl after seating. See Figure 11. 10. After the wedge is properly seated, cycle the lever mechanism "APPLIED" and "RELEASED" a minimum of six (6) times, leaving the pedal in the full "APPLIED" position after the last application. 11. Recheck the wedge to be sure it is fully engaged in its proper position. NOTE: The parking brake light should be off when the parking brake is released. If the light is on with the parking brake released, check the wedge installation (Step 9). Parking Brake Functional Test NOTE: The installation of the lock-in wedge disables the self-adjusting feature of the parking brake control assembly. The following parking brake functional test must be performed to verify proper parking brake system adjustment. 1. Place vehicle on hoist with the transmission in neutral. a. Verify the parking brake is fully released. Check for brake drag by turning the rear wheels by hand. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4547 b. Check for a firm pedal feel while fully applying the parking brakes. 2. If vehicle experiences either brake drag or a "soft" pedal, go to PARKING BRAKE ADJUSTMENT PROCEDURE. Parking Brake Adjustment Procedure NOTE: Perform the following adjustment procedure only if directed here from the Parking Brake Functional Test or only perform Steps 1 thru 4 if wedge removal is required. To perform the parking brake adjustment procedure, the lock wedge must first be removed from the control assembly. Upon completion of the adjustment procedure, the wedge must be reinstalled. 1. To remove the wedge, apply pressure to the pedal until a full travel position is achieved. The pedal will be in a vertical position. 2. Use a pair of standard pliers or needle nose vice grips to grip the tab of the lock-in wedge. WARNING CARE MUST BE USED TO AVOID ACTIVATING THE RELEASE LEVER DURING WEDGE REMOVAL. 3. With a twisting motion, pull out the wedge. 4. Inspect the wedge for damage. If the tab is broken off, if it is missing teeth or if it is severely damaged in any other fashion, discard it. Obtain a new wedge for installation. 5. Release the parking brake. 6. With the vehicle still on a hoist, have an assistant rotate one rear wheel to check for drag while you pull on the appropriate cable until a slight drag is felt at the wheel. a. F-Series/Bronco - pull forward on corresponding rear cable at equalizer. b. Explorer/Ranger - pull forward on front cable. 7. At this point, push rearward on the cable a slight amount until the wheel spins freely. 8. Have the assistant rotate the opposite wheel and adjust the corresponding cable as outlined in steps 6 and 7. 9. Recheck the first wheel to verify correct parking brake adjustment. 10. Apply the parking brake and install wedge as outlined in steps 2-11 of LOCK-IN WEDGE INSTALLATION. 11. Perform PARKING BRAKE FUNCTIONAL TEST. Dealer Letter RECALL NUMBER 94S91 Date: Nov., 1994 PARTS AVAILABILITY At Dealers By: as Req'd 0% of Parts Direct Shipped to Dealers AT PDC By: Now Date in Owner Letter: November, 1994 - phased mail To: All Ford Dealers Subject: Safety Recall 94S91 - Certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger Vehicles equipped Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4548 with Manual Transmission - Installation of a Parking Brake Lock-in Wedge Affected Vehicles: Certain 1992-1994 Model Year Bronco, F150-350 Series Trucks equipped with manual transmissions and produced prior to the following dates: ASSEMBLY PLANT PRODUCTION DATE Norfolk Assembly 1/27/94 Michigan Truck 2/04/94 Ontario Truck 2/09/94 Kentucky Truck 2/16/94 Kansas City Assembly 4/22/94 All 1993-1994 Model Year Ranger/Explorer vehicles with manual transmission produced prior to 5/01/94. Reasons For Recall During rapid pedal application, the parking brake pedal, with little or no effort, may go to the floor and the parking brake may be ineffective in holding the vehicle stationary. Should this occur, the self-adjustment pawl may skip over one or more teeth on the ratchet. To correct this condition, a lock-in wedge will be installed in the parking brake assembly. This wedge locks out the self-adjustment mechanism and retains the adjustment pawl in mesh with the ratchet. WARNING DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY. ALWAYS SET THE PARKING BRAKE FULLY AND TURN OFF THE IGNITION WHEN LEAVING THE VEHICLE. NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Owner Letter November, 1994 Serial Number: 12345678901234567 94S91 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4549 Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-350 Series Trucks and 1993-1994 Model Year Explorer/Ranger vehicles. Safety Defect During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system may not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness. Repairs At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information. WARNING DO NOT PARK THE VEHICLE IN NEUTRAL. USE FIRST (1) GEAR AND SET THE PARKING BRAKE FULLY. NOTE: When the transfer case is in the N (Neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in First (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. How Long Will It Take? The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Truck? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P.O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built truck. Supplement Parking Brake Lock-in Wedge Original - November, 1994 Supplement - May, 1995 Identifies Additional Vehicles Involved Supplement - July, 1995 Identifies Additional Vehicles Involved Dealer Letter To: All Ford Dealers Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4550 Reference: Safety Recall Bulletin 94S91, dated October 25, 1994. Subject: Safety Recall 94S91 Supplement # 1 - Additional Units The purpose of this bulletin is to advise you that 1994 model year Rangers equipped with manual transmission built at Edison Assembly Plant from 5/1/94 through 5/13/94 and 1994 model year Rangers and Explorers equipped with manual transmission built at Louisville Assembly Plant from 5/1/94 through 5/12/94 have been added to the referenced recall. According to our records, the additional involved vehicle(s) shown on the enclosed listing have been delivered to your dealership. Notification Of Owners Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by first class mail. If the owner of any vehicle cannot be contacted or does not make an appointment to have the vehicle corrected, advise your FCSD Regional Office of the owner's name and address so that we can handle further notification. Recall Procedures Refer to the Recall 94S91 Bulletin, dated October 25, 1994 for technical instructions, parts information and reporting procedures. Questions? Claims Information 1-800-423-8851 Technical Assistance 1-800-826-4694 Other Recall Questions 1-800-825-5621 Owner Letter June, 1995 Serial Number: 12345678901234567 94S91 Mr. John Sample 123 Main Street Anywhere, USA 12345 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1992-1994 Model Year Bronco, F-150-35- Series pickup trucks and chassis cabs and 1993-1994 Model Year Explorers and Rangers. Safety Defect During rapid pedal application of the parking brake, the pedal may go to the floor with little or no effort. Should this occur, the parking brake system nay not achieve full tension, potentially resulting in parking brake ineffectiveness, or diminished effectiveness. Repairs At no charge to you, your dealer will install a parking brake lock-in wedge. This wedge retains the adjustment pawl in mesh with the ratchet. Dealers currently have instructions and parts ordering information. Warning Do not park the vehicle in Neutral. Use First (1) gear and set the parking brake fully. (Note: When the transfer case is in the N (neutral) Position, the engine and transmission are disconnected from the rest of the driveline. Therefore, the vehicle is free to roll even if the manual transmission is in gear. Do not leave the vehicle unattended with the transfer case in N (Neutral)). Always set the parking brake fully and turn off the ignition when leaving the vehicle. Make sure that the gearshift is securely positioned in first (1) gear. NOTE: If the parking brake pedal moves to the floor with little or no effort when applied, release and reset the parking brake. Never leave your vehicle unattended while it is running. If you do not take these precautions, your vehicle may move unexpectedly and injure someone. How Long Will It Take? The time needed for this service is about one-half hour. However, due to service scheduling times, your dealer may need your vehicle for one full working day. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > 94S91 > Nov > 94 > Recall - Parking Brake Lock In Wedge Installation > Page 4551 Call Your Dealer Call your dealer without delay. Ask for a service date and whether parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When your bring your truck in, show the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address Or Sold The Truck? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the truck. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center, 300 Renaissance Center, P. O. Box 43360, Detroit, Michigan 48243. You also may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call the toll free Auto Safety Hotline 1-800-424-9393 (Washington, D.C. area residents may call 366-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for safety and satisfaction with your Ford-built truck. Supplement Parking Brake Lock-in Wedge Supplement - July, 1995 Identifies Additional Vehicles Involved Dealer Letter Attachments not Applicable Customer Notification Letter not Applicable Dealer Letter To: All Ford Dealers Reference: Safety Recall Bulletin 94S91, dated October 25, 1994 Subject: Safety Recall 94S91 - Supplement # 2 - Additional Units Affected Vehicles The purpose of this bulletin is to advise you that 1992 model year F-Series 150-350 trucks equipped with manual transmissions built at Twin Cities Assembly Plant from 8/20/91 through 6/12/92 have been added to the referenced recall. According to our records, the additional involved vehicle(s) shown on the enclosed listing have been delivered to your dealership. Notification of Owners Vehicle owners whose names and addresses are shown on the enclosed listing are being notified by first class mail. Dealer-Owner Contact Immediately contact any owner whose name is not on the list. Give the owner a copy of the Owner Letter. Region Contact Advise regional office if: ^ an owner cannot be contacted ^ an owner does not make a service date. Recall Procedures Refer to the Recall 94S91 Bulletin, dated October 25, 1994 for technical instructions, parts information and reporting procedures. Questions? Claims Information 1-800-423-8851 Other Recall Questions 1-800-825-5621 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > NHTSA94V169000 > Aug > 94 > Recall 94V169000: Parking Brake Defect Parking Brake Pedal: All Technical Service Bulletins Recall 94V169000: Parking Brake Defect THE PARKING BRAKE CONTROL SELF-ADJUST PAWL DOES NOT LINE UP PROPERLY WITH THE SELF-ADJUST RACHET CAUSING THE PAWL TO SLIP OVER ONE OR MORE TEETH IN THE RACHET. WHEN THE ABOVE OCCURS, IT CAN RESULT IN PARKING BRAKE SYSTEM IN EFFECTIVENESS. THE PARKING BRAKE WILL NOT HOLD THE VEHICLE, CAUSING THE VEHICLE TO ROLL FREELY, IF THE TRANSMISSION IS NOT LEFT IN GEAR. A WEDGE WILL BE INSTALLED WHICH WILL SERVE TO LOCK THE PARKING BRAKE SELF-ADJUST MECHANISM PAWL INTO ENGAGEMENT WITH THE RACHET. ALSO, OWNERS WILL BE ADVISED TO RELEASE AND RE-APPLY THE PARKING BRAKE WHENEVER TOOTH SKIP OCCURS AND WILL BE REMINDED TO ALWAYS TURN OFF THE ENGINE AND LEAVE THE VEHICLE IN GEAR WHEN THE VEHICLE IS PARKED. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND MULTI-PURPOSE VEHICLES WITH MANUAL TRANSMISSIONS. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1993 FORD TRUCK BRONCO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK RANGER 1993 MAZDA TRUCK NAVAJO 1994 FORD TRUCK BRONCO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK F150 1994 FORD TRUCK F250 1994 FORD TRUCK F350 1994 FORD TRUCK RANGER 1994 MAZDA TRUCK B SERIES 1994 MAZDA TRUCK NAVAJO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Pedal: > NHTSA94V169001 > Aug > 94 > Recall 94V169001: Parking Brake Defect Parking Brake Pedal: All Technical Service Bulletins Recall 94V169001: Parking Brake Defect THE PARKING BRAKE CONTROL SELF-ADJUST PAWL DOES NOT LINE UP PROPERLY WITH THE SELF-ADJUST RACHET CAUSING THE PAWL TO SLIP OVER ONE OR MORE TEETH IN THE RACHET. WHEN THE ABOVE OCCURS, IT CAN RESULT IN PARKING BRAKE SYSTEM IN EFFECTIVENESS. THE PARKING BRAKE WILL NOT HOLD THE VEHICLE, CAUSING THE VEHICLE TO ROLL FREELY, IF THE TRANSMISSION IS NOT LEFT IN GEAR. A WEDGE WILL BE INSTALLED WHICH WILL SERVE TO LOCK THE PARKING BRAKE SELF-ADJUST MECHANISM PAWL INTO ENGAGEMENT WITH THE RACHET. ALSO, OWNERS WILL BE ADVISED TO RELEASE AND RE-APPLY THE PARKING BRAKE WHENEVER TOOTH SKIP OCCURS AND WILL BE REMINDED TO ALWAYS TURN OFF THE ENGINE AND LEAVE THE VEHICLE IN GEAR WHEN THE VEHICLE IS PARKED. SYSTEM: EMERGENCY PARKING BRAKE; MECHANICAL. VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS AND MULTI-PURPOSE VEHICLES WITH MANUAL TRANSMISSIONS. NOTE: IF YOUR VEHICLE IS PRESENTED TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND THE REMEDY IS NOT PROVIDED FREE OF CHARGE WITHIN A REASONABLE TIME OR THE REMEDY DOES NOT CORRECT THE DEFECT, PLEASE CONTACT FORD AT 1-800-392-3673. ALSO, CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-800-424-9393. 1992 FORD TRUCK BRONCO 1992 FORD TRUCK F150 1992 FORD TRUCK F250 1992 FORD TRUCK F350 1993 FORD TRUCK BRONCO 1993 FORD TRUCK EXPLORER 1993 FORD TRUCK F150 1993 FORD TRUCK F250 1993 FORD TRUCK F350 1993 FORD TRUCK RANGER 1994 FORD TRUCK BRONCO 1994 FORD TRUCK EXPLORER 1994 FORD TRUCK F150 1994 FORD TRUCK F250 1994 FORD TRUCK F350 1994 FORD TRUCK RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications Vacuum Brake Booster: Specifications Booster-to-Dash Panel ........................................................................................................................ ............................................... 18-33 Nm (13-25ft lb) Master Cylinder-to-Booster .............................................................................................................................................................. 18-33 Nm (13-25 ft lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4567 Vacuum Brake Booster: Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4568 Vacuum Brake Booster: Description and Operation Item Description 1. Vacuum Hose Connection to Intake Manifold (Part of 2005) 2. Return Spring (Part of 2005) 3. Tandem Power Diaphragms (Part of 2005) 4. Vacuum Port Closed Brakes On (Part of 2005) 5. Filter (Air Inlet) (Part of 2005) 6. Brake Pedal Push Rod (Part of 2005) 7. Atmospheric Port Open Brakes On (Part of 2005) 8. Master Cylinder Push Rod (Part of 2005) PURPOSE In vehicles powered by gasoline engines, vacuum boosters make use of the vacuum produced in the intake manifold to apply additional force to the master cylinder push rod. OPERATION A vacuum booster is a container whose inner space is divided by a diaphragm into two separate chambers. The brake pedal push rod enters on one side, and the master cylinder push rod exits on the other. There are three valves that control the vacuum in the booster. The check valve opens to allow the intake manifold vacuum to evacuate the booster. When it closes, it holds the vacuum in the chambers. The equalizer valve links the two chambers. When it is open, the vacuum in the chambers can equalize; when it closes, the chambers are separated. The vacuum bleed valve functions to reduce the amount of vacuum in chamber B when boost is required. As the brake pedal push rod moves forward, its motion closes the equalizer valve. This isolates chambers A and B, but they are still under vacuum. As the brake pedal push rod moves farther ahead, a port in the brake pedal push rod begins to line up the ports in the sleeve. This vents chamber B to the outside and reduces the amount of vacuum in chamber B. With more vacuum in chamber A and less in chamber B, the diaphragm is forced forward in the direction of the master cylinder push rod, providing a boost. The vacuum bleed valve is not just an open/close valve. A spring located at the forward end of the brake pedal push rod allows the push rod and the sleeve to slide back and forth in relation to each other as the brake pedal is activated. This opens and closes the vent in such a way that only the required amount of vacuum is drawn on. Hard braking bleeds off more vacuum, producing more boost. Light braking generates less boost. Once the level of boost corresponds with the applied pedal force, the bleed valve closes and holds that level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4569 Vacuum Brake Booster: Testing and Inspection VISUAL CHECKS Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be properly secured and in good condition with no holes or collapsed areas. OPERATIONAL CHECKS 1. Check hydraulic brake system for leaks or insufficient fluid. 2. With transmission (7003) in NEUTRAL, stop engine (6007) and apply parking brake control (2780). Apply brake pedal (2455) several times to exhaust all vacuum in the system. 3. Apply brake pedal and hold it in the applied position. Start engine. If vacuum system is operating, brake pedal will tend to move downward under constant foot pressure. If no motion is felt, the power brake booster system is not functioning. Perform a Booster functional test. FUNCTIONAL CHECKS 1. Remove vacuum booster hose from power brake booster and check valve connection. Manifold vacuum should be available at the check valve end of the vacuum booster hose with engine at idle speed and transmission in NEUTRAL. If manifold vacuum is available to the power brake booster, connect vacuum booster hose to power brake booster. 2. With transmission (7003) in NEUTRAL, stop engine (6007) and apply parking brake control (2780). Apply brake pedal (2455) several times to exhaust all vacuum in the system. 3. Apply brake pedal and hold it in the applied position. Start engine. If vacuum system is operating, brake pedal will tend to move downward under constant foot pressure. If no motion is felt, replace the vacuum booster. 4. Operate engine a minimum of 10 seconds at fast idle. Stop engine, and let vehicle stand for 10 minutes. Then, apply brake pedal with approximately 89 N (20 lbs) of force. Brake pedal feel should be the same as that noted with engine operating. If brake pedal feels hard (no power assist), replace check valve and retest. If brake pedal feels spongy, bleed hydraulic system to remove air. Refer to Brake Bleeding. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4570 Vacuum Brake Booster: Adjustments The push rod has an adjustment screw to maintain the correct relationship between the master cylinder push rod and the master cylinder piston. If the push rod is too long it will prevent the master cylinder piston from completely releasing hydraulic pressure, causing the brakes to drag. If the push rod is too short it will cause excessive pedal travel and an undesirable clunk in the booster area. Remove the brake master cylinder for access to the booster push rod. Power Brake Booster Push Rod Adjustment Gauge To check the adjustment of the adjustment screw, fabricate a gauge using the dimensions shown in the illustration, and place it against the master cylinder mounting surface of the booster body as shown below. The engine must be running, with the intake manifold vacuum hose connected to the power brake booster, while checking the adjustment. Adjust the push rod screw by turning the adjustment screw in until the end just touches the inner edge of the slot in the gauge. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4571 Vacuum Brake Booster: Service and Repair Item Part Number Description 1. 2140 Brake Master Cylinder 2. 2L252 Pedal Bracket Assembly 3. 2457 Brake Pedal Pad 4. 02340 Dash Panel 5. 2005 Power Brake Booster 6. 2445 Shift Control Selector Lever and Housing 7. 13480 Stoplight Switch 8. 382802 Nut. Tighten to 18-33 Nm (13-25 ft lb). 9. 353574 Washer 10. 387957 Bushing 11. 2478 Brake Pedal Shaft 12. 97414 Retaining Ring NOTE: The only serviceable components of the power brake booster (2005) are the power brake booster check valve (2365), the adjustable push rod and the rubber reaction disc. The rubber reaction disc can be repositioned if the master cylinder push rod is removed or accidentally pulled out. If the disc cannot be properly installed and aligned, or if it cannot be located within the power brake booster, the power brake booster must be replaced as an assembly. Make sure the booster rubber reaction disc is properly installed if the master cylinder push rod is removed or accidentally pulled out. A dislodged disc may cause excessive pedal travel and extreme operation sensitivity. The disc is black, compared to the silver colored valve plunger that will be exposed after the push rod and front seal is removed. The power brake booster is serviced as an assembly and must be replaced if the reaction disc cannot be properly installed and aligned, or if it cannot be located within the unit itself. REMOVAL 1. Disconnect the stoplamp switch wiring to prevent running the battery down. 2. Support the brake master cylinder (2140) from the underside with a prop. 3. Remove the master cylinder-to-booster retaining nuts. 4. Remove the power brake booster. NOTE: Prior to pedal removal, note the position of the rod. 5. Pull the brake master cylinder off the power brake booster and leave it supported by the prop, far enough away to allow removal of the power brake booster. 6. From inside the cab remove the hairpin retainer and slide the stoplight switch (13480), valve rod, spacers and bushing off the brake pedal arm. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Specifications > Page 4572 7. From inside cab, remove four booster-to-brake and clutch bracket nuts. 8. From engine compartment, remove power brake booster from dash panel. INSTALLATION 1. Put power brake booster in place, sliding four attached bolts through holes in dash panel. 2. From inside the cab, install the booster-to-dash panel retaining nuts. Tighten to 18-33 Nm (13-25 ft lb). 3. Position the brake master cylinder on the power brake booster, and install the retaining nuts. Tighten to 18-33 Nm (13-25 ft lb) and remove the prop from underneath the brake master cylinder. 4. Install the power brake booster check valve. CAUTION: Failure to position the valve rod correctly may cause the rod to bind. 5. From inside the cab install the bushing and position the stoplight switch on the end of the valve rod. CAUTION: When performing the next step, do not substitute other types of pin retainers. Use only factory supplied hairpin retainers. 6. Install the stoplight switch and rod on the pedal arm, along with brake master cylinder push rod spacers (2B129) on each side, and secure with the hairpin retainer. 7. Connect the stoplamp switch wiring. 8. Start the engine (6007) and check brake operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation PURPOSE The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation > Page 4576 Vacuum Brake Booster Check Valve: Testing and Inspection NOTE: This test should only be performed after the brake booster and its vacuum system has been checked and found to be functioning properly. See: Vacuum Brake Booster/Testing and Inspection 1. To test the functioning of the power brake booster check valve: a. Start and run the engine for at least 10 seconds. b. Operate the brake pedal to check for power assist. c. Disconnect the vacuum booster hose from the power brake booster. d. There should be enough vacuum retained in the power brake booster for at least one more power-assisted brake operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #1 Power Distribution Box The 4WABS Relay #1 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > 4 Wheel Anti-Lock Brake System Relay #1 > Page 4582 4WABS Relay: Locations 4 Wheel Anti-Lock Brake System Relay #2 Power Distribution Box The 4WABS Relay #2 is mounted in the underhood power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 4583 4WABS Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Relay <--> [ABS Main Relay] > Component Information > Locations > Page 4584 4WABS Relay: Description and Operation PURPOSE The system relay has two functions, first when the relay is energized, it supplies power to the six valve solenoids in the valve block assembly and the pump motor relay coil. Second, it supplies ground to the ABS warning light when the relay is de-energized. OPERATION The system relay is controlled by the ECU and is energized when it receives an ignition input signal. LOCATION The system relay is located in the fifth position of the relay block behind the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams Brake Fluid Pump Relay: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Diagrams > Page 4588 Brake Fluid Pump Relay: Description and Operation PURPOSE This relay supplies power to the pump motor. OPERATION The relay coil receives power from the system relay and is controlled by the ECU by providing ground to the coil ground. LOCATION The pump motor relay is located in the fifth position of the power network box. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations 4WABS Control Module: Locations All Except Limited Edition And Electronic Group The 4WABS Control Module is located in the engine compartment, behind the driver's side headlamp, mounted on the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4592 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4593 4WABS Control Module: Description and Operation PURPOSE The ECU monitors system operation during normal driving as well as during anti-lock braking. OPERATION Under normal driving conditions, the microprocessors produce short test pulses to check the electrical system without any mechanical reaction. The ECU continuously monitors the speed of each wheel to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ECU signals the appropriate solenoid valve in the hydraulic control unit to open or close as well as the pump motor to turn on and recycle brake fluid back to the master cylinder. This results in moderate pulsations of the brake pedal and pump noise which may be heard in the passenger compartment. During normal braking, the brake pedal feel will be identical to a standard brake system. Most concerns which occur to the anti-lock brake system will be stored as a coded number in the Keep-Alive Memory (KAM) of the ECU. This means that once a code is stored, it will be retained by the ECU even with the key in the OFF position. The codes can be retrieved by following the on-board diagnostic procedures. Refer to Diagnosis and Testing. CONSTRUCTION It is an on-board diagnostic, non-repairable unit consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically. LOCATION The Electronic Control Unit (ECU) is located in the engine compartment behind the driver's side headlamp on a bracket mounted on the surface of the plastic fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > 4WABS Control Module <--> [Electronic Brake Control Module] > Component Information > Locations > Page 4594 4WABS Control Module: Service and Repair REMOVAL 1. Disconnect positive battery cable. 4WABS Electronic Control Unit Location 2. Locate ECU on carbon canister bracket attached to LH fender inner sheet metal. Disconnect 40-pin connector from ECU. 3. Remove screw retaining ECU to mounting bracket. 4. Gently slide ECU along bracket to free rivet and remove ECU. INSTALLATION 1. Insert rivet into large hole portion of teardrop. Gently slide ECU along bracket to engage rivet. 2. Install retaining screw and tighten to 7-9 Nm (5.2-6.6 ft lb). 3. Connect 40-pin connector and tighten bolt to 5.2-7.2 Nm (3.9-5.3 ft lb). NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 4. Connect positive battery cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams Acceleration Sensor: Diagrams Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Acceleration Sensor <--> [Acceleration/Deceleration Sensor] > Component Information > Diagrams > Page 4599 Acceleration Sensor: Description and Operation PURPOSE The G-switch detects and indicates to the anti-lock brake control module whether or not the vehicle is moving. OPERATION The G-switch is used on 4x4 vehicles only. When driven in the 4-wheel drive mode all four wheels are mechanically linked and a situation could arise in which one wheel locks up and causes all four wheels to lock up and skid. The speed sensors would indicate the vehicle speed as zero. Without the G-switch, the anti-lock brake control module (2B373) would have no data to compare and would react as if the vehicle were stopped when in fact it is moving. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, ABS Master Cylinder Reservoir PURPOSE The Master Cylinder Reservoir with Low Fluid Level Warning Switch monitors the fluid level in the master cylinder. OPERATION When a low fluid level condition occurs, a path to ground is provided through the dual brake warning switch to disable the antilock brake system and illuminate the antilock brake indicator. CONSTRUCTION The low fluid level warning switch is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Description and Operation > Fluid Level Sensor, ABS > Page 4604 Brake Fluid Level Sensor/Switch: Description and Operation Fluid Level Sensor, Brakes PURPOSE The fluid level indicator is an integral part of the brake master cylinder reservoir. It is serviced as a part of the brake master cylinder reservoir. CONSTRUCTION It consists of a float and magnet assembly and a reed switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front Axle Sensor: Diagrams Front Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Front > Page 4612 Axle Sensor: Diagrams Rear Connector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Diagrams > Page 4613 Axle Sensor: Description and Operation PURPOSE The anti-lock brake system uses three sets of variable-reluctance sensors and toothed speed sensor rings to determine the rotational speed of each wheel. OPERATION The sensors operate on magnetic induction principle. As the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and sent to the ECU through a twisted-pair wire cable and wiring harness. LOCATION The front sensors are attached to the suspension knuckles, and the speed indicator rings are pressed onto the backside of the rotor. The rear sensor is bolted into the rear axle housing and the rear speed sensor ring is pressed onto the rear axle carrier assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring Axle Sensor: Service and Repair Toothed Ring Front REMOVAL 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. Rotor And Speed Sensor Ring 3. Remove caliper, rotor and hub assemblies. NOTE: Discard speed sensor ring after removal. Do not reuse old ring. Speed Sensor Ring Removal 4. Using a 3-jaw puller, remove indicator ring from hub. INSTALLATION 1. Support center of hub so that wheel studs do not rest on work surface. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4616 Front Speed Sensor Ring Installation 2. Position new speed sensor ring on hub. Using a cylinder with 79mm (3.1 in) ID and 96mm (3.8 in) OD, press the ring onto the hub. The ring must be fully seated against the shoulder in the hub. 3. Install hub, rotor and caliper assemblies. 4. Install wheel and tire assembly. Tighten wheel lugnuts to 115-142 Nm (85-105 ft lb). Rear NOTE: To service the speed sensor ring, the differential case must be removed from the axle housing. REMOVAL 1. Remove the bolts retaining the ring gear to the differential case. Remove the ring gear by striking at alternate holes around the gear. CAUTION: Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock brake sensor ring teeth while handling or during assembly. NOTE: ^ Before removing ring gear inspect it and determine if ring runout check is necessary. ^ Do not remove anti-lock speed sensor ring unless replacement is required. It does not have to be removed for ring gear replacement. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4617 2. If replacement is required remove the anti-lock brake sensor ring by tapping with a soft-faced hammer. Discard the anti-lock speed sensor ring. CAUTION: The anti-lock speed sensor ring must be discarded upon removal. If removed, a new anti-lock brake sensor ring must be installed. INSTALLATION 1. Position the ring gear and anti-lock speed sensor ring on the differential case. The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case as shown. Start two ring gear retaining bolts through the differential case into the ring gear to make sure case-to-ring gear bolt hole alignment is achieved. CAUTION: ^ Extreme care should be taken not to scratch, dent, chip or otherwise cause damage to anti-lock speed sensor ring teeth while handling or during assembly. ^ The tab on the anti-lock speed sensor ring must be aligned with the slot in the differential case. 2. Press the ring gear and anti-lock speed sensor ring on the differential case using the ring gear as a pilot. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4618 3. Coat the threads of the ring gear retaining bolts with Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1. Install the bolts and alternately and evenly tighten to 95-115 Nm (70-85 ft. lbs.). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Axle Sensor <--> [Wheel Speed Sensor] > Component Information > Service and Repair > Toothed Ring > Page 4619 Axle Sensor: Service and Repair Wheel Speed Sensor Front REMOVAL 1. From inside engine compartment, disconnect sensor assembly two-pin connector from wiring harness. 2. Separate sensor cable from brake hose clips. 3. Remove sensor retaining bolt from front spindle and slide sensor out of mounting hole. INSTALLATION For installation, follow removal procedures in reverse order. Tighten retaining bolt to 4.5-6.8 Nm (40-60 in lb). Rear REMOVAL 1. At the rear axle housing pull the wiring harness connector from the speed sensor. 2. Remove the speed sensor hold down bolt and remove the speed sensor from the rear axle housing. INSTALLATION 1. Clean the rear axle housing mounting surface. Use care to prevent dirt from entering the rear axle housing. 2. Inspect and clean the magnetized sensor pole piece to make sure that it is free from loose metal particles which could cause erratico■ system operation. Inspect the speed sensor O-ring for damage and replace if necessary. 3. Lightly lubricate the speed sensor O-ring with motor oil, align the bolt hole, and install. NOTE: Do not apply force to the plastic sensor connector. The sensor flange should slide to the mounting surface. This will make sure the air gap setting is between 0.127-1.143 mm (0.005-0.045 inches). 4. Install the speed sensor hold-down bolt and tighten to 34-40 Nm (25-29 ft. lbs.). 5. Push the connector on the speed sensor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 4625 Clutch Pedal Position Switch: Description and Operation OPERATION The Powertrain Control Module (PCM) sends out a 5 volt reference to the Clutch Pedal Position (CPP) switch. When the switch is "OPEN" (clutch DEPRESSED), the PCM senses voltage. When the switch is "CLOSED" (clutch RELEASED), the PCM senses no voltage. The PCM uses this input to determine engine load and to adjust idle speed accordingly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 4626 Clutch Pedal Position Switch: Service and Repair Fig. 8 Clutch Interlock 3-way Switch REMOVAL 1. Disconnect electrical connector from switch located on clutch master cylinder push rod, Fig. 8. 2. Pull orientation clip away from switch to separate pin, then rotate switch to expose plastic retainer. 3. Push tabs together to allow retainer to slide rearward and separate from switch. 4. Remove switch from push rod. INSTALLATION 1. Install switch onto master cylinder push rod, ensuring that switch is properly seated. 2. Install plastic retainer, then rotate switch into position and attach orientation clip. 3. Connect electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4635 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4636 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4642 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4643 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 4644 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Technical Service Bulletins > Page 4645 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Park/Neutral Position Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 4649 Neutral Safety Switch: Description and Operation PURPOSE The Park/Neutral Position Switch allows driver to start vehicle in PARK or NEUTRAL position of the automatic transmission only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 4650 Neutral Safety Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams > Page 4651 Neutral Safety Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable, then raise and support vehicle. Fig. 6 Neutral Start Switch 2. Disconnect electrical connector from switch, Fig. 6 then remove switch and O-ring using neutral start switch socket T74P-77247-A or equivalent. NOTE: The Neutral start switch socket is a thin wall socket, other types of sockets could puncture walls of switch. INSTALLATION 1. Install neutral start switch using socket and torque to 7-10 ft lb. 2. Connect electrical connector to switch, then lower vehicle. 3. Connect battery ground cable, then check operation of switch with parking brake engaged. Engine should start with selector lever in N or P only, and back-up lamps should illuminate with selector lever in R only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations All Except Limited Edition And Electronic Group The Starter Relay is located at RH front of engine compartment, at fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications Alternator: Electrical Specifications Alternators With Current Ratings of: 40, 40A HE, 60, 65, 75, 80, and 95 Amperes: Volts ..................................................................................................................................................... .................................................................... 15.0 Alternator With Current Rating of: 110 Amperes: Volts ..................................................................................................................................................... ............................................................ 14.1-14.7 Alternator With Current Rating of: 130 Amperes: Volts ..................................................................................................................................................... ........................................................................ -- Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Electrical Specifications > Page 4661 Alternator: Mechanical Specifications Alternators With Current Ratings of: 40, 40A HE, 60, 65, 75, and 80. Regulator ............................................................................................................................................. ................................................................ Internal Slip Ring Turning Minimum Diameter .............................................................................................................................. ........................................................ 1.22 Inch Maximum Runout ........................................................ ............................................................................................................................. 0.0005 Inch Brush Length New ..................................................................................................................................................... ....................................................... 0.480 Inch Wear Limit .................................................................. ................................................................................................................................. 0.25 Inch Alternator With Current Rating of: 95. Regulator ............................................................................................................................................. ................................................................ Internal Slip Ring Turning Minimum Diameter .............................................................................................................................. ........................................................ 1.04 Inch Maximum Runout ........................................................ ............................................................................................................................. 0.0005 Inch Brush Length New ..................................................................................................................................................... ....................................................... 0.709 Inch Wear Limit .................................................................. ................................................................................................................................. 0.12 Inch Alternator With Current Rating of: 110. Regulator ............................................................................................................................................. ................................................................ Internal Slip Ring Turning Minimum Diameter .............................................................................................................................. ........................................................ 0.87 Inch Maximum Runout ........................................................ ..................................................................................................................................... -- Inch Brush Length New ..................................................................................................................................................... ............................................................. -- Inch Wear Limit (Minimum Length) .................................... .............................................................................................................................. 0.315 Inch Alternator With Current Rating of: 130 Regulator ............................................................................................................................................. ................................................................ Internal Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4664 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4665 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4666 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4667 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4668 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4669 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4670 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 4671 Alternator: Connector Views For Integral Alternator Regulator (IAR) Connector Views, please refer to: Starting and Charging/Charging System/Voltage Regulator, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test Alternator: Testing and Inspection Rectifier Short or Grounded and Stator Grounded Test Diode Trio Test Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test > Page 4674 Alternator W/Integral Regulator Rectifier Short Or Grounded & Stator Grounded Test 1. Using a suitable ohmmeter, connect one probe to alternator BAT (B+) terminal and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. - A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. 2. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. - Infinite readings (no needle movement) in all four probe positions in the proceeding tests indicates an open STA terminal lead connection inside the alternator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Rectifier Short or Grounded and Stator Grounded Test > Page 4675 Alternator: Testing and Inspection Field Open or Short Circuit Test Alternator W/Integral Regulator Field Open Or Short Circuit Test 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator "F" terminal screw head with the other probe. 2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9 ohms. 3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other, indicates an open brush lead, worn or stuck brushes, faulty rotor or a loose regulator to brush holder attaching screw. 4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or faulty regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a faulty regulator or loose "F" terminal screw. 6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the regulator "F" terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in one probe direction and approximately 9 ohms in the other. 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or faulty regulator is indicated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Testing and Inspection > Page 4676 Alternator: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect wiring at voltage regulator. 3. Remove attaching nut and wiring terminal from alternator output terminal. 4. Disengage drive belt from alternator. 5. Remove alternator mounting bolts, then the alternator. 6. Reverse procedure to install. Torque bolts to 30-40 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 4681 Clutch Pedal Position Switch: Description and Operation OPERATION The Powertrain Control Module (PCM) sends out a 5 volt reference to the Clutch Pedal Position (CPP) switch. When the switch is "OPEN" (clutch DEPRESSED), the PCM senses voltage. When the switch is "CLOSED" (clutch RELEASED), the PCM senses no voltage. The PCM uses this input to determine engine load and to adjust idle speed accordingly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Diagrams > Page 4682 Clutch Pedal Position Switch: Service and Repair Fig. 8 Clutch Interlock 3-way Switch REMOVAL 1. Disconnect electrical connector from switch located on clutch master cylinder push rod, Fig. 8. 2. Pull orientation clip away from switch to separate pin, then rotate switch to expose plastic retainer. 3. Push tabs together to allow retainer to slide rearward and separate from switch. 4. Remove switch from push rod. INSTALLATION 1. Install switch onto master cylinder push rod, ensuring that switch is properly seated. 2. Install plastic retainer, then rotate switch into position and attach orientation clip. 3. Connect electrical connector. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions Ignition Lock: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4687 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4688 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4689 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > With Key Ignition Lock: Service and Repair With Key NOTE: The following procedure applies to vehicles that have functional lock cylinders, ignition keys available for the vehicle, or ignition key numbers that are known and the proper key can be made. REMOVAL 1. Disconnect battery ground cable, then remove steering wheel. NOTE: Ensure steering wheel is in full up position on models with tilt steering. 2. Turn lock cylinder key to RUN position. 3. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 4. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 5. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 6. Lift top half of shroud from column. Fig. 2 Ignition Lock Cylinder Removal (With Key) 7. Push down on lock cylinder retaining pin using a 1/8 inch diameter wire pin or small punch, then pull lock cylinder from column housing, Fig. 2. 8. Disconnect lock cylinder electrical connector from horn brush electrical connector. INSTALLATION 1. Lubricate lock cylinder with suitable grease, then turn lock cylinder to Run position and depress retaining pin. 2. Insert lock cylinder into housing in flange casting, ensure tab at end of cylinder aligns with slot in ignition drive gear. 3. Turn key to OFF position, allowing cylinder retaining pin to extend into cylinder casting housing hole. 4. Rotate lock cylinder to all positions, ensure cylinder is operating properly. 5. Connect lock cylinder electrical connector to horn brush electrical connector. 6. Position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in lowest position to aid assembly on vehicles with automatic transmission. 7. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 8. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 9. On models with tilt steering, install steering column collar by pressing on top and bottom while installing on column. 10. Install tilt lever and torque to 2.2-3.6 ft. lbs. 11. On all models, install steering wheel. 12. Install lower dash panel trim cover, then connect battery ground cable. 13. Check for proper start in P and N, and ensure vehicle cannot be started in D or R positions and steering wheel locks in LOCK position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > With Key > Page 4697 Ignition Lock: Service and Repair Without Key NOTE: The following procedure applies to vehicles where the ignition lock is inoperative or lock cylinder cannot be rotated due to broken or missing ignition key and the key number is unknown, or the lock cylinder cap is damaged and/or broken so that lock cylinder cannot be rotated. REMOVAL 1. Disconnect battery ground cable, then remove steering wheel. Ensure steering wheel is in full up position on models with tilt steering. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Punch lock cylinder retaining pin using a 1/8 inch maximum diameter prick punch, then drill out retaining pin using a 1/8 inch diameter drill, to a depth of 1/2 inch maximum. CAUTION: Use care not to damage cast housing when drilling out retaining pin. 7. Place a chisel at base of ignition lock cylinder cap, then strike chisel with sharp blows using a suitable hammer to break cap away from lock cylinder. 8. Using a 3/8 inch diameter drill, drill down middle of ignition lock key slot approximately 13/4 inch until lock cylinder breaks loose from steering column cover casting, then remove lock cylinder and drill shavings from base of cover cast housing. Fig. 3 Ignition Lock Bearing Retainer Removal (Less Key) 9. Remove white plastic bearing retainer by inserting a suitable tool with a 90 degrees bend on tip between bearing retainer and bearing and prying upward, Fig. 3. Note position of bearing retainer prior to removal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > With Key > Page 4698 Fig. 4 Ignition Lock Bearing Removal (Less Key) 10. Insert tip of a suitable screwdriver into double-D slot of bearing, Fig. 4, rotate 90°, then remove bearing. Fig. 5 Ignition Lock Drive Gear (Less Key) 11. Remove lock drive gear, Fig. 5, noting relationship of lock drive gear to rack teeth. INSTALLATION 1. Lubricate and position lock drive gear in base of lock cylinder housing in same position as noted during removal. NOTE: Position of lock drive gear is correct if last tooth on drive gear is meshed with last groove on rack. 2. Position bearing in lock cylinder housing, insert tip of screwdriver into double-D slot of bearing, then rotate bearing 90°. 3. Press white plastic bearing retainer into lock cylinder housing, ensure retainer is in its original position, then press firmly to snap into place. 4. Line up flats of drive gear with flats of washer by pulling down on column lock actuator. This will place actuator in RUN position. 5. Lubricate lock cylinder with suitable grease, then turn lock cylinder to ON position and depress retaining pin. 6. Insert lock cylinder into housing in flange casting, ensure tab at end of cylinder aligns with slot in ignition drive gear. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > With Key > Page 4699 7. Turn key to OFF position, allowing cylinder retaining pin to extend into cylinder casting housing hole. 8. Rotate lock cylinder to all positions. Ensure cylinder is operating properly. 9. Connect lock cylinder electrical connector to horn brush electrical connector. 10. Position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in lowest position to aid assembly on vehicles with automatic transmission. 11. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 12. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 13. On models with tilt steering, install steering column collar by pressing on top and bottom while installing on column. 14. Install tilt lever and torque to 2.2-3.6 ft lb. 15. On all models, install steering wheel. 16. Install lower dash panel trim cover, then connect battery ground cable. 17. Check for proper start in P and N, and ensure vehicle cannot be started in D or R positions and steering wheel locks in LOCK position. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4708 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4709 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Ignition Switch: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4715 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4716 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4717 Ignition Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Technical Service Bulletins > Page 4718 Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams Park/Neutral Position Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 4722 Neutral Safety Switch: Description and Operation PURPOSE The Park/Neutral Position Switch allows driver to start vehicle in PARK or NEUTRAL position of the automatic transmission only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 4723 Neutral Safety Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams > Page 4724 Neutral Safety Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable, then raise and support vehicle. Fig. 6 Neutral Start Switch 2. Disconnect electrical connector from switch, Fig. 6 then remove switch and O-ring using neutral start switch socket T74P-77247-A or equivalent. NOTE: The Neutral start switch socket is a thin wall socket, other types of sockets could puncture walls of switch. INSTALLATION 1. Install neutral start switch using socket and torque to 7-10 ft lb. 2. Connect electrical connector to switch, then lower vehicle. 3. Connect battery ground cable, then check operation of switch with parking brake engaged. Engine should start with selector lever in N or P only, and back-up lamps should illuminate with selector lever in R only. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications Starter Motor: Electrical Specifications Starter Diameter .................................................................................................................................. .................................................................. 4 1/2 Inch Ampere Draw Normal Load ............................. ........................................................................................................................................................ 150-180 No-Load Ampere @ 12 Volts ................................................................................................ ........................................................................................... 80 Starter Diameter .................................................................................................................................. ........................................................................ 4 Inch Ampere Draw Normal Load ............................. ........................................................................................................................................................ 150-200 No-Load Ampere @ 12 Volts ................................................................................................ ...................................................................................... 60-85 Starter Diameter .................................................................................................................................. ........................................................................ 4 Inch Ampere Draw Normal Load ............................. ........................................................................................................................................................ 130-220 No-Load Ampere @ 12 Volts ................................................................................................ ...................................................................................... 60-80 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Electrical Specifications > Page 4729 Starter Motor: Mechanical Specifications Starter Diameter .................................................................................................................................. .................................................................. 4 1/2 Inch Engine Cranking Speed ................................... ............................................................................................................................................... 150-290 RPM Brushes Length .......................................................................................................................... ............................................................................. 0.50 Inch Wear Limit .............................................. .............................................................................................................................................................. . 0.25 Inch Spring Tension ................................................................................................................... .................................................................................. 80 Ounces Starter Diameter .................................................................................................................................. ........................................................................ 4 Inch Engine Cranking Speed ................................... ............................................................................................................................................... 180-250 RPM Brushes Length .......................................................................................................................... ............................................................................. 0.50 Inch Wear Limit .............................................. .............................................................................................................................................................. . 0.25 Inch Spring Tension ................................................................................................................... .................................................................................. 80 Ounces Starter Diameter .................................................................................................................................. ........................................................................ 4 Inch Engine Cranking Speed ................................... ............................................................................................................................................... 140-220 RPM Minimum Stall Torque @ 5 Volts ................................................................................................ .......................................................................... 11 Ft Lbs Brushes Length ........................................ .............................................................................................................................................................. . 0.66 Inch Wear Limit .......................................................................................................................... ................................................................................... 0.25 Inch Spring Tension ................................. .............................................................................................................................................................. ...... 64 Ounces Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 4730 Starter Motor: Description and Operation MOTORCRAFT PERMANENT MAGNET STARTERS Exploded View Of Permanent Magnet Starter Motor The starting system includes the permanent magnet gear reduction starter motor with solenoid actuated drive, the battery, a remote control starter switch (Part of the ignition switch), the park/neutral position switch (automatic transmission), clutch pedal position switch (manual transmission), the starter relay, and heavy circuit wiring. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Diagnosis and Testing Starter Motor: Testing and Inspection Diagnosis and Testing Troubleshooting Charts Troubleshooting Chart Starting System Testing Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Diagnosis and Testing > Page 4733 Starting System Testing Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Diagnosis and Testing > Page 4734 Starter Motor: Testing and Inspection No-Load Test The starter No-Load test will uncover such conditions as open or shorted windings, or rubbing armature. The starter can be tested, at no-load, on the test bench only. 1. Make test connections with Rotunda Starting and Charging Tester tool No. 078-00005, or equivalent. Ensure cables connected to starter are sufficient to carry high current flow (the same gauge wire as in vehicle). 2. Set rheostat at maximum counterclockwise position, ensuring no current is flowing through ammeter. Record exact reading on voltmeter. 3. Disconnect starter from battery, then reduce resistance of rheostat until voltmeter indicates same reading as that obtained while starter was running. 4. The ammeter will indicate starter no-load current draw. Refer to electrical specifications for comparison. 5. Check for rubbing armature, bent shaft, binding bearings, or shorts in armature and/or brushes if current exceeds specification. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Diagnosis and Testing > Page 4735 Starter Motor: Testing and Inspection Starter Load Test 1. Connect Rotunda Starting and Charging Tester tool No. 078-00005, or equivalent. Ensure current is not flowing through ammeter and heavy duty carbon pile rheostat portion of circuit (rheostat at maximum counterclockwise position). 2. Disconnect push on "S" terminal at starter relay, then connect remote control starter switch from positive battery terminal and "S" terminal of starter relay. 3. Place transmission in NEUTRAL or PARK (automatic transmission) or fully depress clutch pedal (manual transmission), then crank engine with ignition switch OFF. Record exact reading on voltmeter. 4. Stop cranking engine, then reduce resistance of carbon pile until voltmeter indicates same reading as that obtained while starter cranked the engine. 5. The ammeter will indicate starter current draw under normal load. Compare this value with value listed in electrical specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Testing and Inspection > Diagnosis and Testing > Page 4736 Starter Motor: Testing and Inspection Solenoid Test Using a Digital Volt / Ohmmeter tool No. 007-0001, or equivalent, check for continuity between "S" terminal and " M terminal, and between "S" terminal and ground (frame). If there is no continuity, check for ice, dirt or foreign material preventing contact. Repair or replace solenoid as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal and Installation Starter Motor: Service and Repair Removal and Installation WARNING: WHEN SERVICING STARTER MOTOR OR PERFORMING ANY MAINTENANCE IN THE AREA OF THE STARTER MOTOR, NOTE THE HEAVY GAUGE INPUT LEAD CONNECTED TO THE STARTER SOLENOID IS HOT AT ALL TIMES. MAKE SURE THE PROTECTIVE CAP IS INSTALLED OVER THE TERMINAL AND IS REPLACED AFTER SERVICE. REMOVAL 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect starter cable and push-on connector from starter solenoid. CAUTION: When disconnecting hard-shell connector at S terminal, grasp the plastic shell and pull off. Do not pull on wire. Be careful to pull straight off to prevent damage to the connector and S terminal. If any part of the connection is damaged, replace the damaged components. 4. Remove upper bolt. 5. Remove lower bolt. 6. Remove the starter motor from the vehicle. INSTALLATION 1. Position starter motor to engine and install upper and lower bolt finger-tight. 2. Tighten the upper bolt to 22-28 Nm (16-21 Lb-Ft). 3. Tighten the lower bolt to 22-28 Nm (16-21 Lb-Ft). 4. Connect connector on starter solenoid. Be careful to push straight on and make sure connector locks in position with a notable click or detent. 5. Install starter cable nut to terminal. Tighten to 11-13 Nm (91-122 Lb-In). 6. Replace red safety cap. 7. Lower vehicle to floor. 8. Connect battery ground cable. NOTE: When the Powertrain Control Module (PCM) is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal and Installation > Page 4739 Starter Motor: Service and Repair Disassembly and Assembly NOTE: Although disassembly and service procedures are shown for the starter motor, the starter motor should be returned to Ford Return Parts Center for analysis and review. DISASSEMBLY 1. Remove the M-terminal nut, then slide positive brush connector from M-terminal. 2. Remove the two starter solenoid screws and the starter solenoid. 3. Remove the through-bolts and separate drive end housing from starter frame and magnet. 4. Remove seal from drive end housing. Remove drive assembly from drive end housing. 5. Remove drive lever and pin from starter drive. 6. Remove starter drive stop ring, stop ring retainer and starter drive from output shaft. 7. Pry E-Ring off output shaft, then remove pinion thrust washer and stationary gear. 8. Remove output shaft from starter frame and magnet. Remove planet gear retainer, planet gears, bushing and armature thrust ball from output shaft. NOTE: Armature thrust ball may become dislodged when planet gear retainer, planet gears and bushing are removed from output shaft. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Removal and Installation > Page 4740 9. Remove brush end plate screws. Remove brush end plate and bushing and brush holder. 10. Push starter motor armature out of starter frame and magnet. ASSEMBLY 1. Insert starter motor armature into starter frame and magnet. NOTE: Before inserting starter motor armature into starter frame and magnet apply a thin coat of Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B on both ends of starter motor armature shaft and spline. 2. Install brush holder, making sure brushes fit over commutator. Apply Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B to brush end plate and bushing. 3. Push seal tightly into slot on starter frame and magnet and attach brush end plate and bushing. Insert brush end plate screws and tighten to 2-3 Nm (18-26 Lb-In). 4. Apply Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B to output shaft spline. Install stationary gear, pinion thrust washer and attach output shaft E-ring. 5. Install starter drive, starter drive stop ring and stop ring retainer onto output shaft. Attach drive lever and pin to starter drive. 6. Apply Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B to planet gear and install. Install bushing and armature thrust ball onto output shaft. 7. Apply Syncolon SCC-4-030 or equivalent meeting Ford specification WSF-M1C218-B into drive end housing bearing bore until approximately one-quarter full. Install output shaft into drive end housing, making sure to line up output shaft with hole in drive end housing. 8. Install seal into drive end housing and install planet gear retainer. 9. Position starter frame and magnet to drive end housing and install through-bolts. Tighten through-bolts to 5-10 Nm (45-88 Lb-In). 10. Position starter solenoid to drive end housing, making sure plunger is attached to drive lever and pin. Insert starter solenoid screws and tighten to 5-10 Nm (45-88 Lb-In). 11. Attach positive brush connector to starter solenoid M-terminal. Tighten M-terminal nut to 9-14 Nm (80-123 Lb-In). 12. Check that no-load current draw is within specification. Refer to Component Tests. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations All Except Limited Edition And Electronic Group The Starter Relay is located at RH front of engine compartment, at fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4749 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4750 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4751 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4752 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4753 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4754 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4755 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4756 Circuit Breaker: Electrical Diagrams Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4757 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4758 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 4759 Power Distribution Circuit-To-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 4764 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4773 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4774 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4775 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4776 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4777 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4778 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4779 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4780 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4786 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4787 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4788 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4789 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4790 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4791 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4792 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 4793 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4798 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4799 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4800 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4801 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4802 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4803 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4804 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4805 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Daytime Running Lamps ........................................................................................ .................................................................................................... Fuse 5 Dome/Courtesy Lamp ......... .............................................................................................................................................................. .......................... Fuse 1 Electronic Shift Control Module .................................................................... ............................................................................................................. Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ............................................. Fuse 7 Headlamp Switch ....................................................................... ............................................................................................................................... Fuse 11 Heated Backlite ................................................................................................................................................ ........................................................... Fuse 5 Heated Oxygen Sensor #1 .......................................... ............................................................................................................................................... Fuse 18 Heated Oxygen Sensor #2 .................................................................................................................. ....................................................................... Fuse 18 Heater and A/C Control Assembly ................. ............................................................................................................................................................ Fuse 9 Horn Relay ............................................................................................................................... ................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................. Fuse 8 Instrument Cluster ................................. .............................................................................................................................................................. ........ Fuse 7 Instrument Panel Illumination Lamps ............................................................................. .......................................................................................... Fuse 13 Liftgate Wiper Motor and Switch . .............................................................................................................................................................. .............. Fuse 17 Liftgate Wiper/Washer Switch ................................................................................ .................................................................................................. Fuse 17 Low Oil Level Relay ............ .............................................................................................................................................................. ......................... Fuse 7 Parking/License Lamps ................................................................................. ............................................................................................................ Fuse 10 Power Mirror (Two Door Only) ........................................................................................................................................... ...................................... Fuse 1 Premium Radio Amplifier .................................................................. ....................................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4806 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4807 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4808 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4809 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4810 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4811 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4812 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4813 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4814 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4815 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4816 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4817 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4818 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4819 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4820 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4821 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ..................................... .................................................................................................................................................. Fuse 10 Automatic Day/Night Mirrors ........................................................................................................... ........................................................................ Fuse 17 Backup Lamps .............................................. .............................................................................................................................................................. Fuse 5 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................................................................................... ................................................................................................ Fuse 4 Courtesy Lamp Switches ........ .............................................................................................................................................................. ...................... Fuse 1 Daytime Running Lamps .................................................................................. .......................................................................................................... Fuse 5 Dome/Courtesy Lamp ... .............................................................................................................................................................. ................................ Fuse 1 Electronic Shift Control Module .............................................................. ................................................................................................................. Fuse 17 Electronic Shift Control Module .................................................................................................................................... ............................................. Fuse 7 Electronic Shift Control Switch .................................................. .............................................................................................................................. Fuse 17 Electronic Shift Control Switch ............................................................................................................................. ..................................................... Fuse 7 Headlamp Switch ............................................................... ......................................................................................................................................... Fuse 1 Headlamp Switch ................................................................................................................................. ..................................................................... Fuse 11 Heated Backlite ............................................... ............................................................................................................................................................ Fuse 5 Heated Mirrors ......................................................................................................................... ................................................................................... Fuse 7 Heated Oxygen Sensor #1 .................. .............................................................................................................................................................. ......... Fuse 18 Heated Oxygen Sensor #2 .......................................................................................... ............................................................................................... Fuse 18 Heated Rear Window ............ .............................................................................................................................................................. ........................ Fuse 5 Heater and A/C Control Assembly .................................................................. ........................................................................................................... Fuse 9 Horn Relay ................... .............................................................................................................................................................. ................................. Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 8 Instrument Cluster .............................................................................. ......................................................................................................................... Fuse 1 Instrument Cluster ................................................................................................................................................. .................................................... Fuse 17 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. ........ Fuse 17 Low Oil Level Relay ...................................................................................................... ............................................................................................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Overhead Console .... .............................................................................................................................................................. ..................................... Fuse 5 Parking/License Lamps ..................................................................... ........................................................................................................................ Fuse 10 Power Mirror (Two Door Only) .................................................................................................................................. ............................................... Fuse 1 Premium Radio Amplifier ......................................................... ................................................................................................................................ Fuse 16 Radio Memory (Power supplied through ........................................................................................................ ............................................................ Fuse 2 Radio Memory ............................................................ ................................................................................................................................................ Fuse 1 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 1 Remote Keyless Entry Module ........................ ........................................................................................................................................................... Fuse 6 Speed Control Amplifier ........................................................................................................... .................................................................................. Fuse 6 Stereo Radio and Tape Player ............. .............................................................................................................................................................. ........ Fuse 11 Stop/Hazard Lamps ...................................................................................................... .............................................................................................. Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ........................................................................... ............................................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ...................................................... .................................................................................................................................. Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................. ........................................................... Fuse 5 Turn Lamps ................................................................. ................................................................................................................................................ Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4822 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4823 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4824 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4825 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4826 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4827 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4828 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4829 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4830 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4831 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4832 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4833 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4834 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4835 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4836 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4837 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4838 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4839 Anti-Theft Controller Module ................................................................................................................ ..................................................................... Fuse 6 Autolamps .......................................................... ......................................................................................................................................................... Fuse 2 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch .......................... .............................................................................................................................................................. ........ Fuse 3 Cigar Lighter ................................................................................................................... ............................................................................................ Fuse 3 Courtesy Lamps ......................... .............................................................................................................................................................. ................... Fuse 2 Daytime Running Lamp Module .......................................................................... ..................................................................................................... Fuse 17 Dimmer Flash to Pass Switch .................................................................................................................................................. ................................... Fuse 3 Electronic Shift Control Module ........................................................... ...................................................................................................................... Fuse 7 Fog Lamp Relay .............................................................................................................................................................. .......................................... Fuse 15 Fuel Pump Relay ........................................................................ ............................................................................................................................... Fuse 18 Hazard Flasher ................................................................................................................................................. ........................................................... Fuse 3 Headlamps .................................................................. ................................................................................................................................................ Fuse 2 Heated Rear Window Switch ............................................................................................................... ..................................................................... Fuse 11 Horn ................................................................. ........................................................................................................................................................... Fuse 3 Ignition Switch ......................................................................................................................... .................................................................................. Fuse 1 LH Stop/Turn Signal Relay ................... .............................................................................................................................................................. ..... Fuse 19 Memory Seat Module ...................................................................................................... ........................................................................................... Fuse 8 PCM Power Relay ....................... .............................................................................................................................................................. ............... Fuse 14 PCM Power Relay ................................................................................................. ..................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................................. ...................................... Fuse 2 Power Bolster ................................................................................... .......................................................................................................................... Fuse 8 Power Door Locks ................................................................................................................................................... ................................................... Fuse 6 Power Lumbar ..................................................................... ....................................................................................................................................... Fuse 8 Power Mirrors ...................................................................................................................................... ....................................................................... Fuse 6 Power Seats .................................................... ............................................................................................................................................................. Fuse 8 Powertrain Control Module ...................................................................................................... .................................................................................. Fuse 4 Premium Sound/JBL Amplifier .............. .............................................................................................................................................................. ...... Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4840 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4841 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4842 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4843 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4844 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4845 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4846 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4847 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4848 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4849 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4850 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4851 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4852 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4853 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4854 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4855 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4856 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 4857 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Component Locations The fuse panel is located behind the Lower Left Hand side of the Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4863 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4864 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4865 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4866 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4867 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4868 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Anti-Theft Controller Module .......................................................................................... ........................................................................................... Fuse 6 Autolamps .................................... .............................................................................................................................................................. ................. Fuse 2 Blower Motor Relay ............................................................................................... .................................................................................................... Fuse 5 Brake ON/OFF Switch ........ .............................................................................................................................................................. .......................... Fuse 3 Cigar Lighter ................................................................................................. .............................................................................................................. Fuse 3 Courtesy Lamps ....... .............................................................................................................................................................. ..................................... Fuse 2 Daytime Running Lamp Module ........................................................ ....................................................................................................................... Fuse 17 Dimmer Flash to Pass Switch ..................................................................................................................................... ................................................ Fuse 3 Electronic Shift Control Module .............................................. ................................................................................................................................... Fuse 7 Fog Lamp Relay ......................................................................................................................................... ............................................................... Fuse 15 Fuel Pump Relay ................................................... .................................................................................................................................................... Fuse 18 Hazard Flasher ............................................................................................................................... ............................................................................. Fuse 3 Headlamps ................................................ .............................................................................................................................................................. .... Fuse 2 Heated Rear Window Switch .............................................................................................. ...................................................................................... Fuse 11 Horn ................................................ .............................................................................................................................................................. .............. Fuse 3 Ignition Switch .......................................................................................................... ................................................................................................. Fuse 1 LH Stop/Turn Signal Relay .... .............................................................................................................................................................. .................... Fuse 19 Memory Seat Module ....................................................................................... .......................................................................................................... Fuse 8 PCM Power Relay ........ .............................................................................................................................................................. .............................. Fuse 14 PCM Power Relay .................................................................................. .................................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................... .................................................... Fuse 2 Power Bolster ..................................................................... ........................................................................................................................................ Fuse 8 Power Door Locks ............................................................................................................................... ....................................................................... Fuse 6 Power Lumbar ................................................. ........................................................................................................................................................... Fuse 8 Power Mirrors .......................................................................................................................... ................................................................................... Fuse 6 Power Seats ........................................ .............................................................................................................................................................. ........... Fuse 8 Powertrain Control Module .......................................................................................... .............................................................................................. Fuse 4 Premium Sound/JBL Amplifier .. .............................................................................................................................................................. .................. Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4889 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4890 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4891 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4892 Power Distribution Box Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4893 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4894 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4895 Power Distribution Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4896 Daytime Running Lamps ..................................................................................................................... ....................................................................... Fuse 5 Dome/Courtesy Lamp ...................................... ........................................................................................................................................................... Fuse 1 Electronic Shift Control Module ............................................................................................... .................................................................................. Fuse 7 Electronic Shift Control Switch ............. .............................................................................................................................................................. ....... Fuse 7 Headlamp Switch ............................................................................................................. ......................................................................................... Fuse 11 Heated Backlite ........................... .............................................................................................................................................................. .................. Fuse 5 Heated Oxygen Sensor #1 ................................................................................... ...................................................................................................... Fuse 18 Heated Oxygen Sensor #2 ......................................................................................................................................................... ................................ Fuse 18 Heater and A/C Control Assembly ........................................................ ..................................................................................................................... Fuse 9 Horn Relay ......... .............................................................................................................................................................. ........................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................................. ...................................................... Fuse 8 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. .......... Fuse 7 Parking/License Lamps ................................................................................................ ............................................................................................. Fuse 10 Power Mirror (Two Door Only) . .............................................................................................................................................................. .................. Fuse 1 Premium Radio Amplifier ...................................................................................... ................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4897 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4898 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4899 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4900 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4901 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4902 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4903 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4904 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4905 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4906 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4907 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4908 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4909 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4910 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4911 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4912 Cigar Lighter ........................................................................................................................................ ..................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4913 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4914 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4915 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 10 Automatic Day/Night Mirrors ................. .............................................................................................................................................................. .... Fuse 17 Backup Lamps .................................................................................................................. .......................................................................................... Fuse 5 Blower Motor Relay ...................... .............................................................................................................................................................. ............... Fuse 5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4916 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................... .............................................................................................................................................................. .. Fuse 4 Courtesy Lamp Switches ...................................................................................................... ...................................................................................... Fuse 1 Daytime Running Lamps .................. .............................................................................................................................................................. ............ Fuse 5 Dome/Courtesy Lamp ................................................................................................. ................................................................................................ Fuse 1 Electronic Shift Control Module ................................................................................................................................................. .............................. Fuse 17 Electronic Shift Control Module .............................................................. ................................................................................................................... Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ........................................... Fuse 17 Electronic Shift Control Switch .................................................. ................................................................................................................................ Fuse 7 Headlamp Switch .................................................................................................................................................. ...................................................... Fuse 1 Headlamp Switch .............................................................. ........................................................................................................................................ Fuse 11 Heated Backlite ................................................................................................................................... ........................................................................ Fuse 5 Heated Mirrors ................................................ ............................................................................................................................................................ Fuse 7 Heated Oxygen Sensor #1 ...................................................................................................... ................................................................................... Fuse 18 Heated Oxygen Sensor #2 ................ .............................................................................................................................................................. ........... Fuse 18 Heated Rear Window ................................................................................................ .................................................................................................. Fuse 5 Heater and A/C Control Assembly ............................................................................................................................................. ................................ Fuse 9 Horn Relay .............................................................................................. .................................................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 8 Instrument Cluster ................................................................................................................................................. ...................................................... Fuse 1 Instrument Cluster ............................................................ ......................................................................................................................................... Fuse 17 Instrument Cluster ............................................................................................................................... ........................................................................ Fuse 7 Instrument Panel Illumination Lamps ............. .......................................................................................................................................................... Fuse 13 Liftgate Wiper Motor and Switch ............................................................................................ ................................................................................. Fuse 17 Liftgate Wiper/Washer Switch ............. .............................................................................................................................................................. ....... Fuse 17 Low Oil Level Relay ....................................................................................................... .......................................................................................... Fuse 17 Low Oil Level Relay .................... .............................................................................................................................................................. ................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 1 Overhead Console .............................................................................. ......................................................................................................................... Fuse 5 Parking/License Lamps ....................................................................................................................... ...................................................................... Fuse 10 Power Mirror (Two Door Only) ........................ ......................................................................................................................................................... Fuse 1 Premium Radio Amplifier ......................................................................................................... ................................................................................ Fuse 16 Radio Memory (Power supplied through ................................................................................................................................................ .................... Fuse 2 Radio Memory .................................................................................................... ........................................................................................................ Fuse 1 Remote Keyless Entry Module ................................................................................................................................................. .................................. Fuse 1 Remote Keyless Entry Module ............................................................. ...................................................................................................................... Fuse 6 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................................... ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4917 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4918 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4919 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4920 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4921 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4922 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4923 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4924 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4925 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4926 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4927 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4928 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4929 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4930 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4931 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4932 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 4933 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4938 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4939 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4940 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4941 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4942 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4943 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4944 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 4945 Fusible Link: Electrical Diagrams Fuse Link - protects the following circuits: - From the alternator to the battery and the Power Distribution Box Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Multiple Junction Connector: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4954 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4955 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Multiple Junction Connector: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4961 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 4962 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4965 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4966 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4967 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4968 Multiple Junction Connector: Diagrams Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4969 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4970 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4971 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4972 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4973 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4974 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4975 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4976 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4977 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4978 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4979 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4980 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4981 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4982 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4983 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4984 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4985 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4986 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4987 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4988 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4989 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4990 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4991 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 4992 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 4997 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5007 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5008 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5009 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5010 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5011 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5012 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5013 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5014 Circuit Breaker: Electrical Diagrams Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5015 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5016 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 5017 Power Distribution Circuit-To-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5022 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5031 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5032 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5033 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5034 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5035 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5036 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5037 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 5038 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5044 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5045 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5046 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5047 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5048 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5049 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5050 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 5051 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5056 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5057 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5058 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5059 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5060 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5061 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5062 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5063 Fuse: Electrical Diagrams Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Daytime Running Lamps ........................................................................................ .................................................................................................... Fuse 5 Dome/Courtesy Lamp ......... .............................................................................................................................................................. .......................... Fuse 1 Electronic Shift Control Module .................................................................... ............................................................................................................. Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ............................................. Fuse 7 Headlamp Switch ....................................................................... ............................................................................................................................... Fuse 11 Heated Backlite ................................................................................................................................................ ........................................................... Fuse 5 Heated Oxygen Sensor #1 .......................................... ............................................................................................................................................... Fuse 18 Heated Oxygen Sensor #2 .................................................................................................................. ....................................................................... Fuse 18 Heater and A/C Control Assembly ................. ............................................................................................................................................................ Fuse 9 Horn Relay ............................................................................................................................... ................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................. Fuse 8 Instrument Cluster ................................. .............................................................................................................................................................. ........ Fuse 7 Instrument Panel Illumination Lamps ............................................................................. .......................................................................................... Fuse 13 Liftgate Wiper Motor and Switch . .............................................................................................................................................................. .............. Fuse 17 Liftgate Wiper/Washer Switch ................................................................................ .................................................................................................. Fuse 17 Low Oil Level Relay ............ .............................................................................................................................................................. ......................... Fuse 7 Parking/License Lamps ................................................................................. ............................................................................................................ Fuse 10 Power Mirror (Two Door Only) ........................................................................................................................................... ...................................... Fuse 1 Premium Radio Amplifier .................................................................. ....................................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5064 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5065 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5066 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5067 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5068 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5069 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5070 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5071 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5072 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5073 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5074 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5075 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5076 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5077 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5078 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5079 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ..................................... .................................................................................................................................................. Fuse 10 Automatic Day/Night Mirrors ........................................................................................................... ........................................................................ Fuse 17 Backup Lamps .............................................. .............................................................................................................................................................. Fuse 5 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................................................................................... ................................................................................................ Fuse 4 Courtesy Lamp Switches ........ .............................................................................................................................................................. ...................... Fuse 1 Daytime Running Lamps .................................................................................. .......................................................................................................... Fuse 5 Dome/Courtesy Lamp ... .............................................................................................................................................................. ................................ Fuse 1 Electronic Shift Control Module .............................................................. ................................................................................................................. Fuse 17 Electronic Shift Control Module .................................................................................................................................... ............................................. Fuse 7 Electronic Shift Control Switch .................................................. .............................................................................................................................. Fuse 17 Electronic Shift Control Switch ............................................................................................................................. ..................................................... Fuse 7 Headlamp Switch ............................................................... ......................................................................................................................................... Fuse 1 Headlamp Switch ................................................................................................................................. ..................................................................... Fuse 11 Heated Backlite ............................................... ............................................................................................................................................................ Fuse 5 Heated Mirrors ......................................................................................................................... ................................................................................... Fuse 7 Heated Oxygen Sensor #1 .................. .............................................................................................................................................................. ......... Fuse 18 Heated Oxygen Sensor #2 .......................................................................................... ............................................................................................... Fuse 18 Heated Rear Window ............ .............................................................................................................................................................. ........................ Fuse 5 Heater and A/C Control Assembly .................................................................. ........................................................................................................... Fuse 9 Horn Relay ................... .............................................................................................................................................................. ................................. Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 8 Instrument Cluster .............................................................................. ......................................................................................................................... Fuse 1 Instrument Cluster ................................................................................................................................................. .................................................... Fuse 17 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. ........ Fuse 17 Low Oil Level Relay ...................................................................................................... ............................................................................................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Overhead Console .... .............................................................................................................................................................. ..................................... Fuse 5 Parking/License Lamps ..................................................................... ........................................................................................................................ Fuse 10 Power Mirror (Two Door Only) .................................................................................................................................. ............................................... Fuse 1 Premium Radio Amplifier ......................................................... ................................................................................................................................ Fuse 16 Radio Memory (Power supplied through ........................................................................................................ ............................................................ Fuse 2 Radio Memory ............................................................ ................................................................................................................................................ Fuse 1 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 1 Remote Keyless Entry Module ........................ ........................................................................................................................................................... Fuse 6 Speed Control Amplifier ........................................................................................................... .................................................................................. Fuse 6 Stereo Radio and Tape Player ............. .............................................................................................................................................................. ........ Fuse 11 Stop/Hazard Lamps ...................................................................................................... .............................................................................................. Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ........................................................................... ............................................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ...................................................... .................................................................................................................................. Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................. ........................................................... Fuse 5 Turn Lamps ................................................................. ................................................................................................................................................ Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5080 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5081 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5082 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5083 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5084 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5085 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5086 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5087 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5088 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5089 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5090 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5091 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5092 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5093 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5094 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5095 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5096 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5097 Anti-Theft Controller Module ................................................................................................................ ..................................................................... Fuse 6 Autolamps .......................................................... ......................................................................................................................................................... Fuse 2 Blower Motor Relay ................................................................................................................. .................................................................................. Fuse 5 Brake ON/OFF Switch .......................... .............................................................................................................................................................. ........ Fuse 3 Cigar Lighter ................................................................................................................... ............................................................................................ Fuse 3 Courtesy Lamps ......................... .............................................................................................................................................................. ................... Fuse 2 Daytime Running Lamp Module .......................................................................... ..................................................................................................... Fuse 17 Dimmer Flash to Pass Switch .................................................................................................................................................. ................................... Fuse 3 Electronic Shift Control Module ........................................................... ...................................................................................................................... Fuse 7 Fog Lamp Relay .............................................................................................................................................................. .......................................... Fuse 15 Fuel Pump Relay ........................................................................ ............................................................................................................................... Fuse 18 Hazard Flasher ................................................................................................................................................. ........................................................... Fuse 3 Headlamps .................................................................. ................................................................................................................................................ Fuse 2 Heated Rear Window Switch ............................................................................................................... ..................................................................... Fuse 11 Horn ................................................................. ........................................................................................................................................................... Fuse 3 Ignition Switch ......................................................................................................................... .................................................................................. Fuse 1 LH Stop/Turn Signal Relay ................... .............................................................................................................................................................. ..... Fuse 19 Memory Seat Module ...................................................................................................... ........................................................................................... Fuse 8 PCM Power Relay ....................... .............................................................................................................................................................. ............... Fuse 14 PCM Power Relay ................................................................................................. ..................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................................. ...................................... Fuse 2 Power Bolster ................................................................................... .......................................................................................................................... Fuse 8 Power Door Locks ................................................................................................................................................... ................................................... Fuse 6 Power Lumbar ..................................................................... ....................................................................................................................................... Fuse 8 Power Mirrors ...................................................................................................................................... ....................................................................... Fuse 6 Power Seats .................................................... ............................................................................................................................................................. Fuse 8 Powertrain Control Module ...................................................................................................... .................................................................................. Fuse 4 Premium Sound/JBL Amplifier .............. .............................................................................................................................................................. ...... Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5098 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5099 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5100 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5101 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5102 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5103 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5104 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5105 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5106 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5107 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5108 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5109 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5110 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5111 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5112 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5113 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5114 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5115 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Component Locations The fuse panel is located behind the Lower Left Hand side of the Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5121 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5122 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5123 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5124 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5125 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5126 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5127 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5128 Fuse Block: Electrical Diagrams Circuit-to-Fuse Cross Reference 4WABS Relay #1 ................................................................................................................................. .................................................................... Fuse 10 4WABS Relay #2 .............................................. ......................................................................................................................................................... Fuse 9 4WABS System ....................................................................................................................... ................................................................................. Fuse 13 Alternator/Regulator ............................ .............................................................................................................................................................. ....... Fuse 16 Anti-Theft Controller Module .......................................................................................... ........................................................................................... Fuse 6 Autolamps .................................... .............................................................................................................................................................. ................. Fuse 2 Blower Motor Relay ............................................................................................... .................................................................................................... Fuse 5 Brake ON/OFF Switch ........ .............................................................................................................................................................. .......................... Fuse 3 Cigar Lighter ................................................................................................. .............................................................................................................. Fuse 3 Courtesy Lamps ....... .............................................................................................................................................................. ..................................... Fuse 2 Daytime Running Lamp Module ........................................................ ....................................................................................................................... Fuse 17 Dimmer Flash to Pass Switch ..................................................................................................................................... ................................................ Fuse 3 Electronic Shift Control Module .............................................. ................................................................................................................................... Fuse 7 Fog Lamp Relay ......................................................................................................................................... ............................................................... Fuse 15 Fuel Pump Relay ................................................... .................................................................................................................................................... Fuse 18 Hazard Flasher ............................................................................................................................... ............................................................................. Fuse 3 Headlamps ................................................ .............................................................................................................................................................. .... Fuse 2 Heated Rear Window Switch .............................................................................................. ...................................................................................... Fuse 11 Horn ................................................ .............................................................................................................................................................. .............. Fuse 3 Ignition Switch .......................................................................................................... ................................................................................................. Fuse 1 LH Stop/Turn Signal Relay .... .............................................................................................................................................................. .................... Fuse 19 Memory Seat Module ....................................................................................... .......................................................................................................... Fuse 8 PCM Power Relay ........ .............................................................................................................................................................. .............................. Fuse 14 PCM Power Relay .................................................................................. .................................................................................................................... Fuse 4 Parking and License Lamps .................................................................................................................................... .................................................... Fuse 2 Power Bolster ..................................................................... ........................................................................................................................................ Fuse 8 Power Door Locks ............................................................................................................................... ....................................................................... Fuse 6 Power Lumbar ................................................. ........................................................................................................................................................... Fuse 8 Power Mirrors .......................................................................................................................... ................................................................................... Fuse 6 Power Seats ........................................ .............................................................................................................................................................. ........... Fuse 8 Powertrain Control Module .......................................................................................... .............................................................................................. Fuse 4 Premium Sound/JBL Amplifier .. .............................................................................................................................................................. .................. Fuse 3 RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) .................................................................................................................................... Fuse 19 Remote Keyless Entry Module ............................................................................................................ ....................................................................... Fuse 6 Sub Woofer Amplifier ....................................... ......................................................................................................................................................... Fuse 3 Tail Lamp Relay ....................................................................................................................... ................................................................................ Fuse 19 Under Hood Lamp ................................ .............................................................................................................................................................. ...... Fuse 17 Fuse 1 Fuse 1 - protects the following circuits: - Ignition Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5129 Power Distribution Fuse 2 Fuse 2 - protects the following circuits: - Courtesy Lamps - Headlamps - Parking and License Lamps - Autolamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5130 Power Distribution Fuse 3 Fuse 3 - protects the following circuits: - Hazard Flasher - Brake ON/OFF Switch - Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5131 - Dimmer Flash to Pass Switch - Premium Sound/JBL Amplifier - Sub Woofer Amplifier - Horn Power Distribution Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5132 Fuse 4 - protects the following circuits: - PCM Power Relay - Powertrain Control Module Power Distribution Fuse 5 Fuse 5 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5133 - Blower Motor Relay Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Power Door Locks - Power Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5134 - Anti-Theft Controller Module - Remote Keyless Entry Module Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5135 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Power Seats - Power Lumbar - Memory Seat Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5136 - Power Bolster Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - 4WABS Relay #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5137 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - 4WABS Relay #1 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5138 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5139 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - 4WABS System Diode 14 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5140 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5141 Engine Controls Diode 14 - protects the following circuits: - PCM Power Relay Fuse 15 Fuse 15 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5142 - Fog Lamp Relay Power Distribution Fuse 16 Fuse 16 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5143 - Alternator/Regulator Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Under Hood Lamp - Daytime Running Lamp Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5144 Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Fuel Pump Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5145 Power Distribution Fuse 19 Fuse 19 - protects the following circuits: - LH Stop/Turn Signal Relay - Tail Lamp Relay - RH Stop/Turn Signal Relay (Trailer/Camper Adapter Only) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5146 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5147 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5148 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5149 Power Distribution Box Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5150 Power Distribution Box Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Cigar Lighter .................................... ......................................................................................................................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5151 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5152 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5153 Power Distribution Circuit-to-Fuse Cross Reference All Except Limited Edition and Electronic Group 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Backup Lamps ................................................................................................................................ ............................................................................ Fuse 5 Blower Motor Relay .................................... .............................................................................................................................................................. . Fuse 5 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) ............ .............................................................................................................................................................. ................ Fuse 4 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5154 Daytime Running Lamps ..................................................................................................................... ....................................................................... Fuse 5 Dome/Courtesy Lamp ...................................... ........................................................................................................................................................... Fuse 1 Electronic Shift Control Module ............................................................................................... .................................................................................. Fuse 7 Electronic Shift Control Switch ............. .............................................................................................................................................................. ....... Fuse 7 Headlamp Switch ............................................................................................................. ......................................................................................... Fuse 11 Heated Backlite ........................... .............................................................................................................................................................. .................. Fuse 5 Heated Oxygen Sensor #1 ................................................................................... ...................................................................................................... Fuse 18 Heated Oxygen Sensor #2 ......................................................................................................................................................... ................................ Fuse 18 Heater and A/C Control Assembly ........................................................ ..................................................................................................................... Fuse 9 Horn Relay ......... .............................................................................................................................................................. ........................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................................. ...................................................... Fuse 8 Instrument Cluster ............................................................ ........................................................................................................................................... Fuse 7 Instrument Panel Illumination Lamps .................................................................................................. ..................................................................... Fuse 13 Liftgate Wiper Motor and Switch ...................... ....................................................................................................................................................... Fuse 17 Liftgate Wiper/Washer Switch ............................................................................................... ................................................................................... Fuse 17 Low Oil Level Relay ........................... .............................................................................................................................................................. .......... Fuse 7 Parking/License Lamps ................................................................................................ ............................................................................................. Fuse 10 Power Mirror (Two Door Only) . .............................................................................................................................................................. .................. Fuse 1 Premium Radio Amplifier ...................................................................................... ................................................................................................... Fuse 16 Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) ........................................................................... .............................................................................................................. Fuse 1 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relays .................................................................................................................................................. ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ...................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Power Mirror (Two Door Only) - Dome/Courtesy Lamp - Radio Memory (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5155 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5156 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5157 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Heated Backlite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5158 - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: - Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5159 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module - Electronic Shift Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5160 Power Distribution Fuse 8 All Except Limited Edition and Electronic Group Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5161 Power Distribution Fuse 9 All Except Limited Edition and Electronic Group Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5162 Power Distribution Fuse 10 All Except Limited Edition and Electronic Group Fuse 10 - protects the following circuits: - Parking/License Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5163 - Trailer Park Lamp Relay (Power supplied Fuse 2 of Power Distribution Box) Power Distribution Fuse 11 All Except Limited Edition and Electronic Group Fuse 11 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5164 - Stereo Radio and Tape Player - Headlamp Switch Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5165 Power Distribution Fuse 15 All Except Limited Edition and Electronic Group Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5166 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5167 Power Distribution Fuse 17 All Except Limited Edition and Electronic Group Fuse 17 - protects the following circuits: - Liftgate Wiper/Washer Switch - Liftgate Wiper Motor and Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5168 Power Distribution Limited Edition and Electronic Group Only Fuse 18 All Except Limited Edition and Electronic Group Fuse 18 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5169 - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Power Distribution Circuit-to-Circuit Breaker Cross Reference Interval Wiper Module .......................................................................................................................... ..................................................... Circuit Breaker 2 Wiper Motor ....................................................... ........................................................................................................................................ Circuit Breaker 2 Interval Wiper/Washer Switch ............................................................................................. ....................................................................... Circuit Breaker 2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5170 Cigar Lighter ........................................................................................................................................ ..................................................... Circuit Breaker 12 Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) .................................................................................................................... Circuit Breaker12 Power Windows .............................................................................................................................................. .......................................... Circuit Breaker 14 One-Touch Module ..................................................... .............................................................................................................................. Circuit Breaker 14 Circuit Breaker 2 Circuit Breaker 2 - protects the following circuits: - Interval Wiper Module - Wiper Motor - Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5171 Power Distribution Circuit Breaker 12 Circuit Breaker 12 - protects the following circuits: - Cigar Lighter - Flash to Pass (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5172 Power Distribution Circuit Breaker 14 Circuit Breaker 14 - protects the following circuits: - Power Windows - One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5173 Power Distribution Circuit-to-Fuse Cross Reference 4WABS Control Module ....................................................................................................................... ................................................................... Fuse 15 4WABS Relay #1 ............................................... ..................................................................................................................................................... Fuse 15 Anti-Theft Controller Module ........................................................................................................... .......................................................................... Fuse 6 Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 10 Automatic Day/Night Mirrors ................. .............................................................................................................................................................. .... Fuse 17 Backup Lamps .................................................................................................................. .......................................................................................... Fuse 5 Blower Motor Relay ...................... .............................................................................................................................................................. ............... Fuse 5 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5174 Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) .......................... .............................................................................................................................................................. .. Fuse 4 Courtesy Lamp Switches ...................................................................................................... ...................................................................................... Fuse 1 Daytime Running Lamps .................. .............................................................................................................................................................. ............ Fuse 5 Dome/Courtesy Lamp ................................................................................................. ................................................................................................ Fuse 1 Electronic Shift Control Module ................................................................................................................................................. .............................. Fuse 17 Electronic Shift Control Module .............................................................. ................................................................................................................... Fuse 7 Electronic Shift Control Switch ..................................................................................................................................... ........................................... Fuse 17 Electronic Shift Control Switch .................................................. ................................................................................................................................ Fuse 7 Headlamp Switch .................................................................................................................................................. ...................................................... Fuse 1 Headlamp Switch .............................................................. ........................................................................................................................................ Fuse 11 Heated Backlite ................................................................................................................................... ........................................................................ Fuse 5 Heated Mirrors ................................................ ............................................................................................................................................................ Fuse 7 Heated Oxygen Sensor #1 ...................................................................................................... ................................................................................... Fuse 18 Heated Oxygen Sensor #2 ................ .............................................................................................................................................................. ........... Fuse 18 Heated Rear Window ................................................................................................ .................................................................................................. Fuse 5 Heater and A/C Control Assembly ............................................................................................................................................. ................................ Fuse 9 Horn Relay .............................................................................................. .................................................................................................................... Fuse 8 Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) ............................................................... .......................................................................................................................... Fuse 8 Instrument Cluster ................................................................................................................................................. ...................................................... Fuse 1 Instrument Cluster ............................................................ ......................................................................................................................................... Fuse 17 Instrument Cluster ............................................................................................................................... ........................................................................ Fuse 7 Instrument Panel Illumination Lamps ............. .......................................................................................................................................................... Fuse 13 Liftgate Wiper Motor and Switch ............................................................................................ ................................................................................. Fuse 17 Liftgate Wiper/Washer Switch ............. .............................................................................................................................................................. ....... Fuse 17 Low Oil Level Relay ....................................................................................................... .......................................................................................... Fuse 17 Low Oil Level Relay .................... .............................................................................................................................................................. ................. Fuse 7 Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) ..................................................................................................................................................... .................................... Fuse 1 Overhead Console .............................................................................. ......................................................................................................................... Fuse 5 Parking/License Lamps ....................................................................................................................... ...................................................................... Fuse 10 Power Mirror (Two Door Only) ........................ ......................................................................................................................................................... Fuse 1 Premium Radio Amplifier ......................................................................................................... ................................................................................ Fuse 16 Radio Memory (Power supplied through ................................................................................................................................................ .................... Fuse 2 Radio Memory .................................................................................................... ........................................................................................................ Fuse 1 Remote Keyless Entry Module ................................................................................................................................................. .................................. Fuse 1 Remote Keyless Entry Module ............................................................. ...................................................................................................................... Fuse 6 Speed Control Amplifier ............................................................................................................................................... .............................................. Fuse 6 Stereo Radio and Tape Player ................................................. .................................................................................................................................. Fuse 11 Stop/Hazard Lamps ............................................................................................................................. ....................................................................... Fuse 4 Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) ....................................................................................................... ................................................................................ Fuse 16 Trailer Park Lamp Relay (Power supplied through Fuse 2 of Power Distribution Box ............................................................................. ........................................................................................................... Fuse 10 Trailer Turn Lamp Relay ................................................................................................................................................... ......................................... Fuse 5 Turn Lamps ................................................................................... .............................................................................................................................. Fuse 5 Warning/Chime .................................................................................................................................... ..................................................................... Fuse 17 Warning/Chime ................................................ ........................................................................................................................................................... Fuse 7 Fuse 1 Fuse 1 - protects the following circuits: - Headlamp Switch - Courtesy Lamp Switches - Radio Memory - Remote Keyless Entry Module - Instrument Cluster - Memory Seat Module (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5175 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5176 Power Distribution Fuse 4 Fuse 4 - protects the following circuits: - Stop/Hazard Lamps - Brake ON/OFF Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5177 Power Distribution Fuse 5 Fuse 5 - protects the following circuits: - Turn Lamps - Backup Lamps - Daytime Running Lamps - Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5178 - Heated Rear Window - Blower Motor Relay - Trailer Turn Lamp Relays Power Distribution Fuse 6 Fuse 6 - protects the following circuits: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5179 - Speed Control Amplifier - Remote Keyless Entry Module - Anti-Theft Controller Module Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5180 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5181 Power Distribution Fuse 7 Fuse 7 - protects the following circuits: - Heated Mirrors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5182 Power Distribution Fuse 8 Fuse 8 - protects the following circuits: - Horn Relay - Horn Switch (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5183 Power Distribution Fuse 9 Fuse 9 - protects the following circuits: - Heater and A/C Control Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5184 Power Distribution Fuse 10 Fuse 10 - protects the following circuits: - Parking/License Lamps - Trailer Park Lamp Relay - Autolamp Relay (Power supplied through Fuse 2 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5185 Power Distribution Fuse 11 Fuse 11 - protects the following circuits: - Stereo Radio and Tape Player Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5186 Power Distribution Fuse 13 Fuse 13 - protects the following circuits: - Instrument Illumination Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5187 Power Distribution Fuse 15 Fuse 15 - protects the following circuits: - 4WABS Relay #1 - 4WABS Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5188 Power Distribution Fuse 16 Fuse 16 - protects the following circuits: - Premium Radio Amplifier - Sub Woofer Amplifier (Power supplied through Fuse 3 of Power Distribution Box) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5189 Power Distribution Fuse 17 Fuse 17 - protects the following circuits: - Warning/Chime - Instrument Cluster - Low Oil Level Relay - Electronic Shift Control Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5190 - Electronic Shift Control Switch - Automatic Day/Night Mirrors Power Distribution Fuse 18 Fuse 18 - protects the following circuits: - Heated Oxygen Sensor #1 - Heated Oxygen Sensor #2 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5191 Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions Fusible Link: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5196 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5197 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5198 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5199 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5200 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5201 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5202 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Diagrams > Diagram Information and Instructions > Page 5203 Fusible Link: Electrical Diagrams Fuse Link - protects the following circuits: - From the alternator to the battery and the Power Distribution Box Power Distribution Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch Harness Connector Non-Mating Multiple Junction Connector: Customer Interest Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch Harness Connector Non-Mating > Page 5212 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch Harness Connector Non-Mating > Page 5213 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating Multiple Junction Connector: All Technical Service Bulletins Ignition Switch - Harness Connector Non-Mating Article No. 94-19-7 09/21/94 IGNITION SWITCH - NON-MATING CONDITION BETWEEN 14401 HARNESS CONNECTOR ASSEMBLY AND IGNITION SWITCH - "NEW" SPACER FOR ATTACHING IGNITION WIRING CONNECTION TO SWITCH - VEHICLES BUILT AFTER 5/20/94 - SERVICE TIP FORD: 1994 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1994 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F-150-350 SERIES, F-47, RANGER, VILLAGER ISSUE: Some vehicles may need re-work of the 14401 wiring harness. While attaching the harness connector to the ignition switch, a non-mating condition may occur. This is due to a design revision (larger tower on switch) of the ignition switch, and not having the proper spacer to clear the switch tower. ACTION: While re-working any 14401 harness (on affected vehicles built after 5/20/94), determine if the correct spacer (F4TB-14A468-CA) is attached to the ignition switch connector. The correct spacer will allow the "old" or "new" 14A464 connector to mate with the ignition switch assemblies F2DC-11572-AA or F4DC-11572-AA. Refer to the following service procedures. SERVICE PROCEDURE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 5219 1. Locate connector assembly F4TB-14A464-AYA or F2TB-14A464-VA and inspect to determine if spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A) is attached (Figure 1). NOTE: THE SPACER IS GRAY AND THE PART NUMBER IS EMBOSSED ON THE FACE OF THE SPACER. 2. If spacer F2TB-14A468-HA is being used, please discard by prying off. CAUTION: BE CAREFUL WHEN PRYING OFF THE OLD SPACER, SO THAT THE SPACER LEGS ARE NOT BROKEN OFF INSIDE THE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 94197 > Sep > 94 > Ignition Switch - Harness Connector Non-Mating > Page 5220 CONNECTOR. 3. Snap on the "new" spacer F4TB-14A468-CA (Service Number F4PZ-14A468-A). PART NUMBER PART NAME CLASS F4PZ-14A468-A Spacer Wire Connection (Pk/5) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941907A Inspect And/Or Replace 0.5 Hr. Spacer DEALER CODING BASIC PART NO. CONDITION CODE 14401 11, X8 OASIS CODES: 112000, 203000, 203200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5223 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5224 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5225 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5226 Multiple Junction Connector: Diagrams Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5227 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5228 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5229 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5230 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5231 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5232 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5233 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5234 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5235 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5236 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5237 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5238 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5239 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5240 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5241 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5242 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5243 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5244 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5245 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5246 Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5247 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5248 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5249 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C112 > Page 5250 Connector Identification Connector Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5255 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5259 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5269 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5270 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5271 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5272 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5273 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5274 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5275 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5276 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5282 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5283 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5284 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5285 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5286 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5287 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5288 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 98-5A-22 > Mar > 98 > Vehicle - Pull Or Drift Diagnostics/Service Procedures > Page 5289 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings Alignment: All Technical Service Bulletins Suspension/Steering - Front Alignment Settings Article No. 93-23-24 11/10/93 ^ SUSPENSION - FRONT - ALIGNMENT SETTINGS ^ SUSPENSION - FRONT ALIGNMENT - SERVICE PROCEDURES - 1994 MODEL SERVICE PARTS USAGE LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER ISSUE: Front end alignment on light trucks may occasionally require adjustment. Information about the service parts available to provide the adjustments and service setting objective is featured in this article. ACTION: If light truck Service Manual diagnostics indicate the need for front alignment adjustment, use the optimum alignment settings and caster/camber adjustment parts list provided in this TSB Article. Refer to the appropriate light truck Service Manual, Section 04-00 for service details. DETAILED SERVICE PROCEDURE The chart has been created to give optimum alignment settings and to recommend allowable ranges for all light truck alignments. The ranges recommended in this chart are only recommended guidelines within which most customers would not indicate concern with vehicle alignment. When Service Manual diagnostics indicate that an alignment adjustment may be required to resolve a customer concern, all of the vehicle's alignment parameters should be set to their optimum values to assure customer satisfaction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5294 REQUIRED CONDITIONS BEFORE CHECKING ALIGNMENT: ^ No driver and/or passenger ^ Full fluids ^ All tires set to specified air pressure ^ All tire sizes comparable to original equipment ^ Vehicle configured to normal operated condition (not to exceed max. front GAWR, max. rear GAWR and/or max. GVW. DEFINITIONS 1. Camber Average is defined as LH camber plus RH camber divided by 2 (LH CAMBER + RH CAMBER) / 2. Vehicles set to this specification, as measured with the vehicle loaded to normal loading conditions will result in optimum tire wear. 2. Caster Average is defined as LH caster plus RH Caster divided by 2 (LH CASTER + RH CASTER) / 2. These are NOT recommended values for settings. They are only maximum and minimum limitations. Vehicles outside these limits may exhibit the following: ^ Vehicles which exceed the maximum caster value may result in shimmy concerns. ^ Vehicles operated below the minimum caster value may result in wander and poor steering returnability concerns. 3. Camber Split is defined as LH camber minus RH camber (LH CAMBER - RH CAMBER) 4. Caster Split is defined as LH caster minus RH Caster (LH CASTER - RH CASTER) SPECIAL NOTE - CASTER/CAMBER OUT OF RANGE Vehicles with average caster and/or camber significantly out of specified ranges may have a ride height out of normal operating range. Normal service procedures may not provide adequate adjustment to bring the alignment to the preferred specification. If ride height appears to be an issue, investigate as follows: ^ Front ride height can be below specification if the front loading exceeds the rated capacity listed on the certification label. Weigh the front end and compare to the certification label to determine if an overload condition exists. If overloaded, adjust weight to bring vehicle back into compliance with the published weight limits, or rerate the front suspension within the guidelines of the 1994 Body Builders Layout Book. ^ Front ride height can be abnormally high on lightly loaded vehicles equipped with heavy duty front suspension options or maximum FGAWR options. Compare the ride height of the frame-to-ground guidelines at the wheel centers published in the 1994 Body Builder's Layout Book, and adjust loading as required or revise front suspension rating within the guidelines in the 1994 Body Builder's Layout Book. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5295 The alignment service parts usage chart provides correct parts usage for each type of vehicle. Select the appropriate parts group from these charts and use the caster/camber parts information chart (refer to Figure 1) to order the parts required. For labor times, refer to the 1994 Service Labor Time Standards Manual Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5296 Parts Block OTHER APPLICABLE ARTICLES: 92-25-11, 92-8-13 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings Alignment: All Technical Service Bulletins Suspension/Steering - Front Alignment Settings Article No. 93-23-24 11/10/93 ^ SUSPENSION - FRONT - ALIGNMENT SETTINGS ^ SUSPENSION - FRONT ALIGNMENT - SERVICE PROCEDURES - 1994 MODEL SERVICE PARTS USAGE LIGHT TRUCK: 1994 AEROSTAR, BRONCO, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER ISSUE: Front end alignment on light trucks may occasionally require adjustment. Information about the service parts available to provide the adjustments and service setting objective is featured in this article. ACTION: If light truck Service Manual diagnostics indicate the need for front alignment adjustment, use the optimum alignment settings and caster/camber adjustment parts list provided in this TSB Article. Refer to the appropriate light truck Service Manual, Section 04-00 for service details. DETAILED SERVICE PROCEDURE The chart has been created to give optimum alignment settings and to recommend allowable ranges for all light truck alignments. The ranges recommended in this chart are only recommended guidelines within which most customers would not indicate concern with vehicle alignment. When Service Manual diagnostics indicate that an alignment adjustment may be required to resolve a customer concern, all of the vehicle's alignment parameters should be set to their optimum values to assure customer satisfaction. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5302 REQUIRED CONDITIONS BEFORE CHECKING ALIGNMENT: ^ No driver and/or passenger ^ Full fluids ^ All tires set to specified air pressure ^ All tire sizes comparable to original equipment ^ Vehicle configured to normal operated condition (not to exceed max. front GAWR, max. rear GAWR and/or max. GVW. DEFINITIONS 1. Camber Average is defined as LH camber plus RH camber divided by 2 (LH CAMBER + RH CAMBER) / 2. Vehicles set to this specification, as measured with the vehicle loaded to normal loading conditions will result in optimum tire wear. 2. Caster Average is defined as LH caster plus RH Caster divided by 2 (LH CASTER + RH CASTER) / 2. These are NOT recommended values for settings. They are only maximum and minimum limitations. Vehicles outside these limits may exhibit the following: ^ Vehicles which exceed the maximum caster value may result in shimmy concerns. ^ Vehicles operated below the minimum caster value may result in wander and poor steering returnability concerns. 3. Camber Split is defined as LH camber minus RH camber (LH CAMBER - RH CAMBER) 4. Caster Split is defined as LH caster minus RH Caster (LH CASTER - RH CASTER) SPECIAL NOTE - CASTER/CAMBER OUT OF RANGE Vehicles with average caster and/or camber significantly out of specified ranges may have a ride height out of normal operating range. Normal service procedures may not provide adequate adjustment to bring the alignment to the preferred specification. If ride height appears to be an issue, investigate as follows: ^ Front ride height can be below specification if the front loading exceeds the rated capacity listed on the certification label. Weigh the front end and compare to the certification label to determine if an overload condition exists. If overloaded, adjust weight to bring vehicle back into compliance with the published weight limits, or rerate the front suspension within the guidelines of the 1994 Body Builders Layout Book. ^ Front ride height can be abnormally high on lightly loaded vehicles equipped with heavy duty front suspension options or maximum FGAWR options. Compare the ride height of the frame-to-ground guidelines at the wheel centers published in the 1994 Body Builder's Layout Book, and adjust loading as required or revise front suspension rating within the guidelines in the 1994 Body Builder's Layout Book. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5303 The alignment service parts usage chart provides correct parts usage for each type of vehicle. Select the appropriate parts group from these charts and use the caster/camber parts information chart (refer to Figure 1) to order the parts required. For labor times, refer to the 1994 Service Labor Time Standards Manual Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > 932324 > Nov > 93 > Suspension/Steering - Front Alignment Settings > Page 5304 Parts Block OTHER APPLICABLE ARTICLES: 92-25-11, 92-8-13 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 303000, 304000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5305 Alignment: By Symptom Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5306 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5307 f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5308 NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5309 NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5310 Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5311 ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5312 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5313 ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Technical Service Bulletin # 98-5A-22 Date: 980318 Vehicle - Pull Or Drift Diagnostics/Service Procedures Article No. 98-5A-22 03/18/98 ^ BRAKES - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE ^ STEERING - PULL OR DRIFT - DIAGNOSTIC AND SERVICE PROCEDURE LIGHT TRUCK: 1988-94 RANGER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5314 1991-94 EXPLORER ISSUE: A comprehensive pull and drift diagnostic procedure has been developed to assist technicians with vehicle service. ACTION: Use the following Service Procedure to resolve drift and pull concerns. Proceed with the Pull and Drift Diagnostic Procedure it the pull or drift is not significantly reduced or where there is a case of steady state drift (no braking). A Diagnostic Check List has been provided at the end of this article to use with this procedure. NOTE: THIS TSB ARTICLE SHOULD BE READ COMPLETELY BEFORE PERFORMING DIAGNOSTICS OR REPAIRS. PART NUMBER PART NAME F7AZ-3F823-A Premium Power Steering Fluid D7AZ-19A331-A Silicone Brake caliper Grease And Dielectric Compound F1TZ-3B203-B Radius Arm Bushing (2 Req'd.) F2TZ-2C15O-A Caliper Pin (4 Req'd.) OTHER APPLICABLE ARTICLES: 90-7-16, 89-21-10 SUPERSEDES:98-1-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 985A22A Service Procedure 1.3 Hr. 985A22B Road Test 0.3 Hr. 985A22C Procedure 1 1.9 Hr. 985A22D Procedure 2 2.4 Hr. 985A22E Procedure 3 0.5 Hr. 985A22F Procedure 4 0.9 Hr. 985A22G Procedure 6 2.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE PROCEDURE 1 - TIRE 07 PROCEDURE 2 - FRONT W6 PROCEDURE 3 - TIRE 07 PROCEDURE 4 - 3524 07 PROCEDURE 5 - FRONT W6 PROCEDURE 6 - 2005 42 PROCEDURE 7 - FRONT W6 ROAD TEST - FRONT W6 OASIS CODES: 301000, 303000 Service Procedure 1. Check and adjust brake pad clearances and caliper knuckle clearances as follows: a. Remove the pins from the caliper. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5315 b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015"). c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle. NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION. d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies. e. Remove the anti-rattle clip from the inner pad. f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5316 g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3). CAUTION: DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING. h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2). CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS. 2. During reassembly: ^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel ^ Polish with crocus cloth ^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1) ^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A) NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS. 3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details. Pull/Drift Diagnostic Procedure The Pull/Drift Diagnostic Procedure should be used if the pull or drift is not significantly reduced with the service procedure or in cases of a steady state drift (no braking). Test drive the vehicle with the customer to understand his/her pull or drift concern. Many customers will call a clear vision concern a pull or drift because the steering wheel is not straight. Pull or drifts come from various sources, each with a particular set of symptoms. Careful road test evaluation usually will pinpoint which cause (or causes) is present. Road Test It is important to test drive the vehicle with the customer to UNDERSTAND HIS OR HER CONCERN. Complete the road test before beginning any repairs since you may have multiple causes that need to be identified. ^ The road test should be done on a flat, straight road and should be done in both directions to account for wind ^ Tire pressure should be checked and adjusted, if necessary Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5317 ^ A second person in the vehicle during the road test is helpful. Unless otherwise directed, the second person must remain in the front RH passenger location ^ On vehicles with automatic locking hubs, it is necessary to drive 6 meters (20 feet) forward and then backward to unlock the hubs NOTE: IT IS POSSIBLE THAT THE VEHICLE MAY HAVE MULTIPLE SYMPTOMS. A ROAD TEST/CAUSE CHART. NOTE: RECONNECT THE FLUID LEVEL SENSOR AFTER ROAD TEST. Diagnostic Procedure # 1 - Tire Mismatch Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to Regular Production Option (RPO) list and set tire psi to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Set tire pressure to value on the certification label. 1. Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Tire Pull - Swap the front tires from side-to-side and road test. If the concern is not corrected, continue with next Step. 3. Tire Pull - Swap rear tires from side-to-side and road test. If the concern is not corrected, continue with next Step. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5318 4. Tire Pull - Swap front tires from front to rear. Set the tire pressure to the required pressure for the new front and rear positions, then road test. NOTE: ON REAR LIMITED SLIP AXLE (FRONT HUB UNLOCKED) DRIFT CONCERNS, IT MAY BE NECESSARY TO MEASURE TIRE CIRCUMFERENCE AND PLACE A MATCHED SET OF TIRES ON THE REAR AXLE. Diagnostic Procedure # 2 - Alignment Wheel Alignment - Measure the front wheel alignment. For out-of-specification vehicles, align to the "1991-94 Preferred Alignment Specifications" stated in this article. ^ Spin the front tires to be sure that the front hubs are unlocked. If hubs are unlocked, the axle shaft will not rotate with the wheels ^ Do not adjust wheel alignment to correct for brake pull if the vehicle does not have pull during non-brake applications ^ Set the tire pressure to the specification on the certification label Compare the installed tires and wheels to the certification label. If the tires and wheels match, continue with the Diagnostic Procedure. ^ IF THE TIRES AND WHEELS DO NOT MATCH THE CERTIFICATION LABEL, compare tires and wheels to RPO list and set tire pressure to the correct value ^ IF THE TIRES AND WHEELS DO NOT MATCH CERTIFICATION LABEL OR RPO AVAILABILITY, swap known good tires and wheels (as called for by the certification label or RPO list) for the purposes of evaluation only Drive vehicle after alignment is performed. ^ Vehicles which exceed the maximum average caster value shown above may result in shimmy concerns ^ Vehicles operated below the minimum average caster value shown can result in wander and poor steering returnability concerns If the vehicle is not within these minimum and maximum average caster values, or if the vehicle has experienced any of these listed steering/handling concerns, the average caster should be set in accordance with ride height/caster chart in the Service Manual. Diagnostic Procedure # 3 - Tires 1. Spin the front tires to be sure that the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5319 2. Measure tire circumference of all four (4) tires; put the two (2) closest circumference tires on the rear axle. Tire pressure must be equal on all tires. Diagnostic Procedure # 4 - Steering Gear Valve Off Center Rotary Valve Centering Check: To confirm that you are looking at a steering gear valve concern, lift the front wheels off the ground. ^ The vehicle should be raised so that there is no interference with the steering linkage ^ The front wheels should also spin freely With the wheels in a straight ahead position, start the engine and observe any steering wheel or linkage movement when the engine is started. If any movement is observed, continue with the rotary valve centering check. 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Install a 0-13,790 kPa (0-2000 psi) pressure gauge (Rotunda 014-00207, Power Steering Analyzer) in the pressure line between the power steering pump outlet port 1 and the integral steering gear inlet port. Make sure the valve on the gauge is fully open. 3. Check the fluid level in the reservoir. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 4. Start the engine and turn the steering wheel from stop-to-stop to bring the steering lubricant to normal operating temperature. Turn off the engine and recheck the fluid level. Add Premium Power Steering Fluid F7AZ-3F823-AA or equivalent meeting Ford specification ESW-M2C33-F, if necessary. 5. With the engine running at approximately 1000 rpm and the steering wheel centered, attach a b-in torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 6. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 lb-in), remove the steering gear and replace the shaft and control assembly. 7. Remove the pressure gauge installed in Step 2. Diagnostic Procedure # 5 - RBS Linkage If the RBS linkage is determined to have wind up or memory steer, replace RBS linkage with greaseable steel linkage. NOTE: ALL SERVICE PART STEERING LINKAGE IS THE GREASEABLE STEEL SOCKET TYPE Diagnostic Procedure # 6 - Brake Imbalance 1. Spin the front tires to make sure the front hubs are unlocked. If the hubs are unlocked, the axle shaft will not rotate with the wheels. 2. Check for front wheel rotational drag with warm/hot brakes. a. Make a series of 10 stops from speeds of 48 km/h (30 mph). b. Make the 10 stops with no more than 30 second intervals between stops. This generally will induce a maximum pull if there is a drift/pull concern. c. Raise the front end of the vehicle so that both tires are off the ground. d. Rotate the front wheels by hand. NOTE: FOR ALL 4-WHEEL-DRIVE VEHICLES, MAKE SURE THE HUBS ARE DISENGAGED. Both tires should rotate about the same amount, with little brake drag occuring. Some brake drag will naturally be present for each size of vehicle. 3. If the vehicle has excess brake drag, proceed as follows: a. Open the bleed screw on the affected wheel to check for residual pressure in the brake lines. If there is a squirt of brake fluid out of the bleeder screw and the drag is reduced or eliminated, the master cylinder may not be allowing the brake fluid to return to the reservoir. b. Check the master cylinder push rod adjustment. Refer to the appropriate Service Manual, Section 06-06, for service details. c. Check the brake pedal to determine if it is fully returning. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5320 4. Remove both calipers and check piston retraction using a C-clamp and wooden block. The piston should easily move back into the bore under the force of the clamp. Rebuild or replace as needed. 5. If Steps 1 through 4 have not determined the concern, swap rotors and linings from side-to-side. NOTE: SHOE TAB CLEARANCES SHOULD BE CHECKED AND MODIFIED IF NEEDED. REFER TO FIGURE 2. 6. Test drive the vehicle with 10 or more stops from 64 km/h (40 mph) before evaluating for brake drift. If there is no change in drift while braking, it may be assumed the concern is not the result of the front brakes. 7. Check the rear brakes. Remove the rear wheels and brake drums. a. Check for contaminants (i.e., grease, axle lube, leaking brake fluid, etc.). b. Check for broken components, frozen parking brake cables or improperly installed parts. c. Check the cage diameter using the Brake Shoe Adjustment Gauge (D81L-1103-A). If either side is out-of-specification, check for proper function of the adjusting mechanism and repair or replace as required. d. Check the rear wheel cylinders by the following method. ^ Replace one of the brake drums ^ Have another person apply the brakes and watch for movement of one of the brake shoes on the other wheel ^ Reapply the brakes while holding in place the shoe that moved. The opposite shoe should now move. If no movement is observed, repair or replace the wheel cylinder ^ Reinstall the drum and repeat the procedure for the other rear brake 8. If the condition still exists, swap rear shoes from side-to-side and drive the vehicle. If the drift is significantly reduced, replace the rear linings. If the pull/drift is not significantly reduced, go to Service Procedure # 7. Diagnostic Procedure # 7 - Miscellaneous Check for loose, damaged or excessively worn parts. Visually inspect the front suspension for loose or worn components (i.e., ball joints, radius arm bushings, radius arm attachments at the axle and frame, alignment adjusters, steering linkage, etc.). Repair or replace as required. Diagnostic Check List NOTE: THE FOLLOWING CHECK LIST SHOULD BE COMPLETED AFTER EACH STEP OF THE DIAGNOSTIC WHERE APPLICABLE. SERVICE PROCEDURE 1. Checking clearances ___ Caliper-to-knuckle clearance. ___ Inner shoe side and end clearance. 2. Lubrication of components ___ Lubrication of the caliper rails and inner knuckle pad grooves. 3. Radius arm bushings ___ Replacement of right and left side radius arm bushings. DIAGNOSTIC PROCEDURE 1. Tire mismatch ____ Unlocked hubs check. ____ Front tires swapped side-to-side. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Other Service Bulletins for Alignment: > Page 5321 ____ Rear tires swapped side-to-side. ____ Front-to-rear tire swap. 2. Alignment ____ Unlocked hubs check. ____ Toe changed to ____. ___ Caster changed and split is ____. ___ Camber changed and split is ____. 3. Tire circumference ____ Unlocked hubs check. ___ Tire circumference checked and two (2) closest circumference tires swapped to rear axle. 4. Steering gear valve ____ Unlocked hubs check. ____ Install pressure gauge. ____ Check fluid level with engine off and on. ___ Apply torque to the steering wheel nut and check gauge readings. ___ Replaced the shaft and control assembly. ____ Removed the pressure gauge. 5. RABS linkage ____ Replaced the RBS linkage. 6. Brake imbalance ____ Unlocked hubs check. ____ Front wheel rotational drag check. ____ Master cylinder check. ____ Piston retraction check. ____ Rotors and linings swapped from side-to-side. ____ Rear brakes checked. ___ Rear drums and shoes swapped from side-to-side. 7. Miscellaneous ___ Check for loose, damaged or worn parts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5322 Alignment: Specifications Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Alignment: Service and Repair Camber 1. Measure caster and camber, noting difference between specification and actual measurement. Fig. 1 Caster/Camber Variation Chart 2. Select correct service adjuster, Fig. 1. Select adjuster that will bring alignment to specifications with the smallest side to side variation. 3. Remove front wheel and tire assembly. 4. Remove upper ball joint pinch bolt, then using removal tool No. T64P-3590-F or tool No. D81T-3010-B or equivalent, remove adjuster. 5. Install new adjuster, then using suitable 11/2 inch socket rotate adjuster to specified position. 6. Install ball joint pinch bolt torquing to 48-65 ft lb, install snap ring. 7. Install front wheel and tire assembly, then recheck alignment. NOTES: ^ Caster and camber adjustment is possible with adjusters available in 1/2°, 1° and 11/2° increments. ^ One adjuster is used to adjust both caster and camber. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5325 Alignment: Service and Repair Caster 1. Measure caster and camber, noting difference between specification and actual measurement. Fig. 1 Caster/Camber Variation Chart 2. Select correct service adjuster, Fig. 1. Select adjuster that will bring alignment to specifications with the smallest side to side variation. 3. Remove front wheel and tire assembly. 4. Remove upper ball joint pinch bolt, then using removal tool No. T64P-3590-F or tool No. D81T-3010-B or equivalent, remove adjuster. 5. Install new adjuster, then using suitable 11/2 inch socket rotate adjuster to specified position. 6. Install ball joint pinch bolt torquing to 48-65 ft lb, install snap ring. 7. Install front wheel and tire assembly, then recheck alignment. NOTES: ^ Caster and camber adjustment is possible with adjusters available in 1/2°, 1° and 11/2° increments. ^ One adjuster is used to adjust both caster and camber. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5326 Alignment: Service and Repair Preliminary Inspection Inspect the following components, adjust, repair or replace as required prior to performing front wheel alignment. 1. Inflate tires to cold specifications. 2. Ensure front tires are of same size, ply rating and load rating. 3. Inspect for excessive wheel bearing endplay. 4. Inspect for worn or damaged spindle ball joints. 5. Inspect steering gear mounting bolts for proper torque. 6. Inspect radius arm or bent or damaged condition. 7. Inspect radius arm to frame bushings for looseness or wear. 8. Inspect suspension components for wear or damage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5327 Alignment: Service and Repair Toe 1. Loosen clamp bolts at each end of spindle connecting rod tube, then rotate the sleeve until correct toe alignment of 1/32 inch is obtained. Fig. 4 Toe-In Adjustment 2. Center clamps between adjustment sleeve nibs, then position bolts horizontally with clamps nuts positioned as shown in Fig. 2. 3. Recheck toe-in adjustment, then check that steering wheel spokes are properly positioned and adjust as necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5328 Alignment: Service and Repair Vehicle Lean Correction Front Lean NOTE: Codes identifying the front and rear spring options and springs are printed on the Safety Standard Certification Label. If a spring requires replacement because of damage or sagging, replace only with the same part as specified on the label. In rare instances, the spring codes will not reflect the springs as installed due to a DSO option or Assembly Plant substitution. if a DSO option number is shown on the certification label, the district office can establish whether springs are affected. If the factory-installed springs do not agree with the code printed on the Safety Standard Certification Label (right and left spring part number should match), it is advisable to replace springs in pairs. 1. Measure the left and right front ride heights by measuring the height of the right and left front fender lip openings. Add 8 mm (5/16 inch) to the right side ride height measurement. 2. Compute the difference between left and right ride heights as figured in Step 1 above. a. If the difference exceeds 3-9 mm (1/8-3/8 inch) and is less than 19 mm (3/4 inch) measured at the wheelhouse opening to ground, add 1 shim to the side of the vehicle that is low. b. The shim is to be placed under the lower spring seat; service shim (part number 389117-S2) can be used without a front stabilizer bar. c. If there is a computed side-to-side difference of 19 mm (3/4 inch) or more in the left/right wheelhouse openings, swap front coil springs from side-to-side. If the lean condition follows the spring (lean now on other side of the vehicle), replace both springs with new ones. d. Changing front ride height by adding the service shim also affects caster angles. Adding the 4.5 mm thick shim (part number 389117-S2 or equivalent) may reduce caster by up to 0.40 degrees on the side to which the shim is added. Rear Lean With the underslung rear suspension, use of shims will not have any effect on a lean condition. Use the following procedure to verify and correct a rear lean condition. 1. Measure rear ride height by measuring the height of the right and left rear fender lip openings. 2. Compute the difference. 3. Inspect the vehicle for any excess loads which might weigh the vehicle down on one side more than the other. Usually a weight of at least 50 pounds is required to cause such a lean. 4. If lean condition is not caused by weight, swap the rear springs from side-to-side. 5. If the lean changes sides, the lean condition is most likely caused by a bad spring. Replace both springs. 6. If the lean condition did not change when the springs were changed, factors other than suspension are the cause. Side-to-Side Lean Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5329 1. Side-to-side vehicle lean should be verified by measuring the fender lip-to-ground dimensions A and B. Normal acceptable limits are: a. Maximum of 16 mm (5/8 inch) variance between left and right front wheel lips to ground. b. Maximum of 19 mm (3/4 inch) variance between left and right rear wheel lips to ground. 2. Once a lean condition has been verified, perform the following steps. a. Place the vehicle on a flat, smooth surface. Vehicles must be sitting on the wheels and tires, not on a hoist, jack or jack stands. b. Inspect vehicle for any heavy add-ons that may cause excessive weight on any corner of the vehicle. Vehicle should be empty, fuel tanks full, no cargo in the pick-up box or rear body section. c. Check all wheels and tires: - Wheel size and design, tire size and tread should be indicated on the Vehicle Safety Standard Certification Label. - Wheels must be same size and design, right and left side, on each axle. - Tires must be same brand, tire size, tread design and equal tread wear side-to-side on each axle. - Check air pressure of all tires; inflate to specifications indicated on the Vehicle Safety Standard Certification Label. d. Check front and rear suspension. Verify the same spring is on left/right front and left/right rear. - Front coil springs have I.D. tags indicating the part number. - Rear springs have the part number stamped on the bottom left just behind the U-bolt attachment. - If I.D. tags are missing from the front springs, there is no sure way of identifying which springs are installed on the vehicle. It is advisable to order springs in pairs only. e. Bounce the vehicle's front and rear suspension to normalize the vehicle static ride height. f. Measure the height of the right and left fender lip openings again. If the differences are still greater than 16 mm (5/8 inch) between left or right front and/or 19 mm (3/4 inch) between left and right rear, factors other than suspension are the cause. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Verify power steering pump has been properly filled, then start and run engine until it reaches normal operating temperature. Turn steering wheel to the left and right several times without hitting the stops. Recheck fluid level. If any air bubbles are present, bleed system as follows: 1. Disable ignition by disconnecting coil wire or ICM. 2. Disconnect shutoff solenoid to prevent starting. 3. Crank engine for 30 seconds, check fluid level and add if required. 4. Crank engine for 30 seconds while cycling steering wheel lock to lock. Do not hold steering wheel on its stops. 5. Check fluid level and add fluid if required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications Minimum Relief Pressure, psi .............................................................................................................. ......................................................................... 1050 Maximum Relief Pressure, psi .......................... ............................................................................................................................................................ 1230 Minimum Flow, Gallons/Minute @ 740 psi [01] ........................................................................................................................................................... 0.95 Maximum Free Flow @ 1500 RPM ............................................................................................. .................................................................................... 2.6 [01] -- Flow depends on pump model, engine RPM & pulley drive ratio. Engine RPM must be set to specification when checking pump minimum flow capacity. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5338 Power Steering Pump: Description and Operation The Ford CII power steering pump is a belt-driven slipper type pump with a fiberglass reinforced nylon power steering oil reservoir. The oil reservoir is attached to the rear side of the pump housing front plate and the power steering pump housing is encased within the housing and reservoir. The power steering pressure hose is attached with a quick connect fitting, located below the filler neck at the outboard side of the power steering oil reservoir. The fitting allows the line to swivel and does not indicate a loose fitting. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5339 Power Steering Pump: Service and Repair Exploded View Of Power Steering Pump DISASSEMBLE 1. Remove pulley from pump. 2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove reservoir. 3. Place a suitable C-clamp in a vise. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5340 4. Position lower support plate tool No. T78P-3733-A2, or equivalent, over pump rotor shaft. 5. Install upper compressor plate tool No. T78P-3733-A1, or equivalent, into upper portion of C-clamp. Fig. 2 Positioning Pump In C-Clamp 6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing downward. 7. Tighten C-clamp until a slight bottoming of valve cover is observed. Fig. 3 Removing Valve Cover Retaining Ring 8. Through small hole located on side of pump housing, insert a suitable drift and push inward on valve cover snap ring. While pushing inward on snap ring, place a screwdriver under snap ring edge and remove ring from housing. 9. Loosen C-clamp and remove upper compressor plate tool No. T78P-3733-A2, or equivalent, then remove pump assembly. 10. Remove pump valve cover and O-ring. 11. Remove rotor shaft, upper plate, cam and rotor assembly and two dowel pins. 12. Remove lower plate and spring, by tapping housing on a flat surface. 13. Using a suitable screwdriver, remove rotor shaft seal. ASSEMBLE 1. Position rotor on rotor shaft splines with triangle detent on rotor counterbore facing upward. 2. Install snap ring into groove on end of rotor shaft. 3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5341 Fig. 4 Installing Slipper Springs 4. With rotor extended upward approximately half out of cam, insert spring into rotor picket. Fig. 5 Installing Slippers 5. Use a slipper to compress spring, then install slipper with groove facing cam. 6. Perform Steps 4 and 5 on slipper cavity beneath opposite inlet recess. 7. While holding cam stationary, index rotor left or right one space and install another spring and slipper until all ten rotor cavities have been filled. Ensure rotor springs and slippers remain in position while turning. 8. Apply Loctite(R) Adhesive part No. 242 or 271, or equivalent, to outside diameter of seal and Lockquick(R) NF or T primer, or equivalent, to seal bore in housing. Install rotor shaft seal using seal installer tool No. T78P-3733-A3, or equivalent. Using a plastic mallet, drive seal into bore until properly seated. 9. Position pump plate on flat surface with pulley side facing downward. 10. Install two dowel pins and spring into housing. Spring must be inserted with dished surface facing upward. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5342 11. Lubricate inner and outer O-ring seals with power steering fluid, then install seals on lower pressure plate. 12. Install lower pressure plate into housing and over dowel pin with O-ring seals facing toward front of pump. Position assembly on C-clamp. Place seal installer tool No. T78P-3733-A3, or equivalent, into rotor shaft hole and press on lower plate lightly until it bottoms in pump housing. This will seat outer O-ring seal. Fig. 6 Assembling Cam, Slippers And Rotor 13. Install cam, rotor and slippers and rotor shaft assembly into pump housing over dowel pins. When installing assembly into pump housing, stepped holes must be used for dowel pins and notch in cam insert must be toward reservoir and approximately 180 degrees opposite square mounting lug on housing. Upper Pressure Plate Installation 14. Position upper pressure plate over dowel pins with recess directly over recessed notch on cam insert and approximately 180 degrees opposite Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5343 square mounting lug. 15. Lubricate O-ring seal with power steering fluid. Then, position O-ring on valve cover. Ensure plastic baffle is securely in position on valve cover. A coat of petroleum jelly may be used to hold baffle in position. Fig. 8 Installing Valve Cover 16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with square mounting lug on housing. 17. Place assembly in C-clamp and compress valve cover into pump housing until snap ring groove on housing is exposed. 18. Install valve cover snap ring in pump housing. Ensure snap ring ends are near access hole in pump housing. 19. Remove pump assembly from C-clamp. 20. Lubricate O-ring seal with power steering fluid, then place seal on pump housing. 21. Install reservoir on pump housing. 22. Install flow control valve and spring into valve cover. 23. Lubricate O-ring seals with power steering fluid, then place seals on outlet fitting. 24. Install outlet fitting on valve cover. Torque outlet fitting to 25-34 ft lb. Use care not to cock flow control valve when installing. Do not force valve forward otherwise damage to housing may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation Steering Gear: Description and Operation Fig. 1 Ford Integral Power Steering Gear The Ford XR-50 power steering unit is a torsion bar type of hydraulic-assisted system. This system furnishes power to reduce the amount of turning effort required at the steering wheel. It also reduces road shock and vibrations. Fig. 2 Ball And Nut Housing The unit includes a worm and one piece rack-piston which is meshed to the gear teeth on the steering sector shaft. The unit also includes a hydraulic valve, actuator, input shaft and torsion bar assembly which are mounted on the end of the worm shaft and operated by a twisting action of the torsion bar. This rotary valve type gear, uses a one piece rotary valve and sleeve assembly. Therefore no centering shims are used and no adjustment is possible. This makes possible internal fluid passages between valve and cylinder, thus eliminating all external lines and hoses except the pressure and return hoses between pump and gear. The power cylinder is an integral part of the gear housing. The piston is double acting in that fluid pressure may be applied to either side of the piston. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Rotary Valve Centering Inspection Steering Gear: Adjustments Rotary Valve Centering Inspection 1. Install a 2000 psi pressure gauge in pressure line between pump outlet port and steering gear inlet port. Make sure valve on gauge is in fully open position. 2. Check fluid level in reservoir and replenish as required. 3. Start engine and cycle steering wheel from stop-to-stop to bring steering lubricant up to normal operating temperature. Stop engine and recheck reservoir. Add fluid as necessary. 4. With engine running at a fast idle speed (1000 RPM) and steering wheel centered, attach an inch pound torque wrench to steering wheel retaining nut. Apply sufficient torque to wrench in each direction (either side of center) to get a gauge reading of 250 psi. 5. Torque reading should be the same in both directions. If difference between readings exceeds 6 in lb, remove steering gear from vehicle and replace shaft and control assembly. The "out-of-vehicle" procedure for centering check is the same as for the "in-vehicle" except torque and simultaneous pressure reading must be made at right and left stops instead of either side of center. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Adjustments > Rotary Valve Centering Inspection > Page 5353 Steering Gear: Adjustments Sector and Rack Teeth Lash NOTE: Preload (thrust bearing adjustment) and worm-to-rack preload cannot be changed in service. The only adjustment that can be performed is the total overcenter position load to eliminate excessive lash between sector and rack teeth. 1. Disconnect pitman arm from sector shaft. 2. Disconnect fluid return line at reservoir and cap reservoir return line pipe. 3. Place end of return line in a clean container and cycle steering wheel in both directions as required to discharge fluid from gear. 4. Carefully remove airbag assembly from steering wheel hub, then turn steering wheel 45 degrees from right stop. 5. Using an inch pound torque wrench on steering wheel nut, determine torque required to rotate shaft slowly through approximately 1/8 turn from 45 degrees position. 6. Turn steering gear back to center, then determine torque required to rotate shaft back and forth across center position. 7. Adjust if meshload required to rotate shaft back and forth across center position is less than 10 in lb greater than the force required to rotate shaft from 45 degrees to stop. Loosen adjusting nut and turn adjusting screw until reading is 9-13 in lb greater than torque measured 45 degrees from stop. Hold screw in place, then tighten locknut. 8. Check readings, then install pitman arm and steering wheel cover. 9. Connect fluid return line and replenish reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal Steering Gear: Service and Repair Removal 1. Disconnect the pressure and return lines from the steering gear. Plug the lines and the ports in the gear to prevent entry of dirt. 2. Remove the upper and lower steering gear shaft U-joint shield from the flex coupling. Disconnect the flex coupling at the steering gear by removing the bolt. 3. Raise the vehicle and remove the Pitman arm attaching nut, and washer. 4. Remove the Pitman arm from the sector shaft using Tool T64P-3590-F, Pitman Arm Remover. Remove the tool from the Pitman arm. CAUTION: Do not damage the seals. 5. Support the steering gear, and remove the steering gear attaching bolts. 6. Work the steering gear free of the flex coupling. Remove the steering gear from the vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5356 Steering Gear: Service and Repair Disassembly CAUTION: Uses clean workbench and tools. - Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid, if, necessary. - Handle all parts carefully to avoid nicks, burrs:, scratches and dirt. - Do not use solvent on seals. 1. Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear. 2. Secure the gear in a soft-jawed vise. 3. Remove the nut from the sector shaft adjusting screw. 4. Turn the input shaft to either stop, then turn it back two turns to center the gear. NOTE: The indexing flat on the input shaft spline should he facing downward. 5. Remove the sector shaft cover attaching bolts. 6. Tap the lower end of the sector shaft with soft-hammer to loosen it, and lift the cover and shaft from the housing as an assembly. Discard the O-ring. 7. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw. (It may he necessary to hold the screw with a screwdriver.) 8. Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve and piston assembly and control valve gasket. Discard the gasket. NOTE: If valve housing or the valve sleeve seals are to he replaced, proceed to Step 11. If sector shaft seals are to he replaced go to steering gear housing section.See: Steering Gear Housing The balls need to he removed if the valve sleeve rings are to he replaced. 9. With the piston held so that the bail guide faces up, remove the ball guide clamp screws and ball guide clamp. With a finger over the opening in the ball guide, turn the piston so that the ball guide faces down over a clean container. Let the guide tubes drop into the container. 10. Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then he removed from the piston. Inspect the piston bore to insure all balls have been removed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5357 11. Install the valve body assembly in the Bench Mounted Holding Fixture, Tool T57L-500-B, or equivalent and loosen the Allen head race nut screw from the valve housing. Remove the worm hearing race nut using Adjuster and Locknut Wrench Tool T66P-3553-B or equivalent and Spacer -Valve Housing to Piston Tool T66P-3553-C or equivalent. 12. Carefully slide the input shaft, worm and valve assembly out of the valve housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5358 Steering Gear: Service and Repair Assembly 1. Mount the valve hosing in the bench mounted holding fixture, Tool T57L-5O0-B, with the flanged end up. 2. Apply a light coat of Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve. 3. Carefully install the worm shaft and valve in the housing. 4. Install the worm bearing race nut in the housing and tighten to 75 - 122 N.m (55 90 ft. lbs.). 5. Install the Allen head race nut set screw through the valve housing and tighten to specification 1.7 - 2.8 N.m (15 - 25 in. lbs.). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5359 Fig. 3 Installing Piston On Worm Shaft 6. Place the power cylinder piston on the bench with the bell guide holes facing up. Insert the worm shaft into the piston so that the first groove is in line with the hole nearest the center of the piston. 7. Place the ball guides in the piston. Turning the worm shaft counterclockwise as viewed from the input end of the shaft, place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop, rotate the input shaft in one direction, then the other while inserting the remaining balls. 8. Secure the guides in the ball nut with the clamp. Tighten screws to 4.8 - 7.9 N.m (42 - 70 in. lbs.). 9. Apply petroleum jelly or equivalent to the Teflon seal on the piston. 10. Place a new control valve O-ring on the valve housing. 11. Slide the piston and valve into the gear housing being careful not to damage the piston ring. 12. Align the oil passage in the valve housing with the passage in the gear housing. Places new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install, but do not tighten, the attaching bolts. identification tag is to be installed under upper right valve housing bolt. 13. Rotate the ball nut so that the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 41 - 62 N.m (30 - 45 ft. lbs.). 14. Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston. 15. Apply petroleum jelly or equivalent to the sector shaft journal, and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75 - 94 N.m (55 - 70 ft. lbs.). 16. Attach an in. lb. torque wrench to the input shaft. Adjust meshload to specification. Refer to specifications.See: Adjustments/Meshload Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5360 Steering Gear: Service and Repair Installation 1. Install the lower U-joint shield onto the steering gear lugs. 2. Slide the upper U-joint shield into place on the steering shaft assembly. Turn the steering wheel so the spokes are in the horizontal position. 3. Center the steering gear input shaft with the indexing flat facing down. 4. Slide the steering gear input shaft into the flex coupling and into place on the frame side rail. install the attaching bolts and lighten to 68-84 N.m (50 - 62 ft. lbs.). Tighten the flex coupling bolt to 34 - 47 N.m (26 - 34 ft. lbs.). 5. Be sure the wheels are in the straight ahead position, then install the Pitman arm on the sector shaft. Install the Pitman arm attaching washer and nut. Tighten nut to 230 - 310 N.m (170 - 228 ft.lbs.). 6. Connect and tighten the pressure and the return lines to the steering gear to 27 - 40 N.m (20 30 ft. lbs.). 7. Snap the upper and lower steering gear shaft U-joint shields together. 8. Disconnect the coil wire. Fill the reservoir. Crank the engine by Operating the ignition switch in START mode while turning the steering wheel from left to right to distribute the fluid. 9. Re-check fluid level and add Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent, if necessary. - Connect the coil wire, start the engine and turn the steering wheel from side to side. Inspect for fluid leaks. Re-check fluid level. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5361 Steering Gear: Service and Repair Removal 1. Disconnect the pressure and return lines from the steering gear. Plug the lines and the ports in the gear to prevent entry of dirt. 2. Remove the upper and lower steering gear shaft U-joint shield from the flex coupling. Disconnect the flex coupling at the steering gear by removing the bolt. 3. Raise the vehicle and remove the Pitman arm attaching nut, and washer. 4. Remove the Pitman arm from the sector shaft using Tool T64P-3590-F, Pitman Arm Remover. Remove the tool from the Pitman arm. CAUTION: Do not damage the seals. 5. Support the steering gear, and remove the steering gear attaching bolts. 6. Work the steering gear free of the flex coupling. Remove the steering gear from the vehicle. Disassembly CAUTION: Uses clean workbench and tools. - Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid, if, necessary. - Handle all parts carefully to avoid nicks, burrs:, scratches and dirt. - Do not use solvent on seals. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5362 1. Hold the steering gear upside down over a drain pan and cycle the input shaft several times to drain the fluid from the gear. 2. Secure the gear in a soft-jawed vise. 3. Remove the nut from the sector shaft adjusting screw. 4. Turn the input shaft to either stop, then turn it back two turns to center the gear. NOTE: The indexing flat on the input shaft spline should he facing downward. 5. Remove the sector shaft cover attaching bolts. 6. Tap the lower end of the sector shaft with soft-hammer to loosen it, and lift the cover and shaft from the housing as an assembly. Discard the O-ring. 7. Turn the sector shaft cover counterclockwise and remove it from the sector shaft adjuster screw. (It may he necessary to hold the screw with a screwdriver.) 8. Remove the valve housing attaching bolts and identification tag. Lift the valve housing off the steering gear housing. Remove the valve and piston assembly and control valve gasket. Discard the gasket. NOTE: If valve housing or the valve sleeve seals are to he replaced, proceed to Step 11. If sector shaft seals are to he replaced go to steering gear housing section.See: Steering Gear Housing The balls need to he removed if the valve sleeve rings are to he replaced. 9. With the piston held so that the bail guide faces up, remove the ball guide clamp screws and ball guide clamp. With a finger over the opening in the ball guide, turn the piston so that the ball guide faces down over a clean container. Let the guide tubes drop into the container. 10. Rotate the input shaft from stop to stop until all balls fall from the piston into the container. The valve assembly can then he removed from the piston. Inspect the piston bore to insure all balls have been removed. 11. Install the valve body assembly in the Bench Mounted Holding Fixture, Tool T57L-500-B, or equivalent and loosen the Allen head race nut screw from the valve housing. Remove the worm hearing race nut using Adjuster and Locknut Wrench Tool T66P-3553-B or equivalent and Spacer -Valve Housing to Piston Tool T66P-3553-C or equivalent. 12. Carefully slide the input shaft, worm and valve assembly out of the valve housing. Assembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5363 1. Mount the valve hosing in the bench mounted holding fixture, Tool T57L-5O0-B, with the flanged end up. 2. Apply a light coat of Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the Teflon rings on the valve sleeve. 3. Carefully install the worm shaft and valve in the housing. 4. Install the worm bearing race nut in the housing and tighten to 75 - 122 N.m (55 90 ft. lbs.). 5. Install the Allen head race nut set screw through the valve housing and tighten to specification 1.7 - 2.8 N.m (15 - 25 in. lbs.). Fig. 3 Installing Piston On Worm Shaft 6. Place the power cylinder piston on the bench with the bell guide holes facing up. Insert the worm shaft into the piston so that the first groove is in Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5364 line with the hole nearest the center of the piston. 7. Place the ball guides in the piston. Turning the worm shaft counterclockwise as viewed from the input end of the shaft, place the same balls as removed in Step 9 of Steering Gear Disassembly in the ball guide. During assembly 27 to 29 balls are required. If all the balls have not been inserted upon reaching the left stop, rotate the input shaft in one direction, then the other while inserting the remaining balls. 8. Secure the guides in the ball nut with the clamp. Tighten screws to 4.8 - 7.9 N.m (42 - 70 in. lbs.). 9. Apply petroleum jelly or equivalent to the Teflon seal on the piston. 10. Place a new control valve O-ring on the valve housing. 11. Slide the piston and valve into the gear housing being careful not to damage the piston ring. 12. Align the oil passage in the valve housing with the passage in the gear housing. Places new O-ring onto the oil passage hole of the gear housing. Install identification tag onto the housing. Install, but do not tighten, the attaching bolts. identification tag is to be installed under upper right valve housing bolt. 13. Rotate the ball nut so that the teeth are in the same plane as the sector teeth. Tighten the valve housing attaching bolts to 41 - 62 N.m (30 - 45 ft. lbs.). 14. Position the sector shaft cover O-ring in the steering gear housing. Turn the input shaft to center the piston. 15. Apply petroleum jelly or equivalent to the sector shaft journal, and position the sector shaft and cover assembly in the gear housing. Install the sector shaft cover attaching bolts. Tighten the bolts to 75 - 94 N.m (55 - 70 ft. lbs.). 16. Attach an in. lb. torque wrench to the input shaft. Adjust meshload to specification. Refer to specifications.See: Adjustments/Meshload Installation 1. Install the lower U-joint shield onto the steering gear lugs. 2. Slide the upper U-joint shield into place on the steering shaft assembly. Turn the steering wheel so the spokes are in the horizontal position. 3. Center the steering gear input shaft with the indexing flat facing down. 4. Slide the steering gear input shaft into the flex coupling and into place on the frame side rail. install the attaching bolts and lighten to 68-84 N.m (50 - 62 ft. lbs.). Tighten the flex coupling bolt to 34 - 47 N.m (26 - 34 ft. lbs.). 5. Be sure the wheels are in the straight ahead position, then install the Pitman arm on the sector shaft. Install the Pitman arm attaching washer and nut. Tighten nut to 230 - 310 N.m (170 - 228 ft.lbs.). 6. Connect and tighten the pressure and the return lines to the steering gear to 27 - 40 N.m (20 30 ft. lbs.). 7. Snap the upper and lower steering gear shaft U-joint shields together. 8. Disconnect the coil wire. Fill the reservoir. Crank the engine by Operating the ignition switch in START mode while turning the steering wheel from left to right to distribute the fluid. 9. Re-check fluid level and add Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent, if necessary. - Connect the coil wire, start the engine and turn the steering wheel from side to side. Inspect for fluid leaks. Re-check fluid level. Flushing Flushing the steering gear is required when installing a repaired power steering pump. 1. Remove the power steering pump and remove the power steering pump rotor. 2. Install the power steering pump rotor on the repaired power steering pump. Install the power steering pump and connect only the power steering pressure hose to the power steering pump. 3. Place the power steering return hose from the steering gear in a suitable container and plug the power steering fluid reservoir return tube. 4. Fill the power steering fluid reservoir with MERCON(R) Power Steering Fluid. 5. Disconnect the ICM connector to prevent the engine from starting and raise the front wheels off the ground. 6. While approximately two quarts of steering gear fluid are being poured into the reservoir, crank the engine using the ignition switch. At the same Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5365 time, cycle the steering wheel from stop to stop. Do not hold the steering wheel against a stop for more than three to five seconds at a time. 7. As soon as all of the fluid has been poured in, turn the ignition switch off and attach the ICM connector. NOTE: Be careful to avoid excessive cranking as the battery will be drained and the starter motor damaged. 8. To clear fault codes, disconnect the battery for one minute, and then reconnect the battery. NOTE: When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 9. Remove the plug from the power steering oil reservoir return tube, and attach the power steering return hose to the power steering fluid reservoir. 10. Check the power steering fluid reservoir fluid level, add fluid to the proper level. 11. Start the engine and cycle the steering from stop to stop to expel any trapped air from the system. In Vehicle Adjustment Adjust total over center position load to eliminate excessive lash between the sector and rack teeth as follows. See meshload specifications for checking and setting valuesSee: Adjustments/Meshload. This is the only adjustment required. 1. Disconnect the Pitman arm from the sector shaft using Tool T64P-3590-F, Pitman Arm Puller. 2. Disconnect the fluid return line at the reservoir and cap the reservoir return line pipe. 3. Place the end of the return line in a clean container and turn the steering wheel from stop to stop several times to discharge the fluid from the gear. Discard the fluid. 4. Turn the steering wheel to 45° (degrees) from the right stop. 5. Attach an in. lb. torque wrench to the steering wheel nut and determine the torque required to rotate the shaft slowly approximately one-eighth turn from the 45° (degrees) position toward center. 6. Turn the steering gear back to center and determine the torque required to rotate the shaft back and forth across the center position (±90° (degrees)). See the end of this section for checking and re-setting specifications. If re-set is required, loosen the adjuster locknut and turn the sector shaft adjuster screw until the reading is the specified value greater than the torque at 45° (degrees) from the stop. Hold the sector shaft screw in place, and tighten the locknut. 7. Re-check the torque readings and replace the Pitman arm and steering wheel hub cover. 8. Connect the fluid return line to the reservoir and fill the reservoir. Adjust belt tension, if necessary. CAUTION: Do not pry against the reservoir to obtain proper belt load. Pressure may deform the reservoir and cause It to leak. Meshload During the vehicle breaking-in period, some factory settings may change. These changes in settings will not necessarily affect operation of the steering gear assembly. If excessive steering lash is encountered, then a meshload adjustment may be required. Rotary Valve 1. Install a 0 - 13,789 kPa (0 - 2000 psi) pressure-gauge (Tool D79L-33610-A, Power Steering Analyzer) in the pressure line between the power steering pump outlet port and the integral steering gear inlet port. Be sure that the valve on the gauge is fully open. 2. Check the fluid level in the reservoir and add Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent, if necessary. 3. Start the engine and turn the steering wheel from stop-stop to bring the steering fluid to normal operating temperature. Turn off the engine and re-check the fluid level. Add Premium Power Steering fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent if necessary. 4. With the engine running at approximately 1000 rpm and the steering wheel centered, attach an in. lb. torque wrench to the steering wheel nut. Apply sufficient torque in each direction to get a gauge reading of 1723 kPa (250 psi). 5. The torque wrench readings should be the same in both directions at 1723 kPa (250 psi). If the difference between the readings exceeds 0.68 N.m (6 in.lbs.), remove the steering gear and replace the shaft and control assembly (-3D517-). 6. When performing the valve spool centering check outside the vehicle, use the procedures described above, except take the torque and pressure readings at the right and left stops instead of either side of center. NOTE: A hissing noise is a normal characteristic of rotary valve steering gears and in no way affects steering. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5366 - Do not replace the shaft and control assembly unless the hiss is EXTREMELY objectionable. - A replacement valve will also exhibit slight noise, and is not usually a cure for the complaint. - Any metal-to-metal contacts, such as column grounding, coupling grounding, or sheet metal to steering components will transmit valve hiss noise into the passenger compartment. - The only service that can be performed on the 3D517 valve assembly is the replacement of the four valve sleeve O-rings on the valve sleeve and replacement of the control valve housing. Disassembly Remove the Teflon piston seal and O-ring from the piston and ball nut. Discard both seals. Assembly 1. Dip anew O-ring in Standard Transmission Lubricant (SAE-8OW) D8DZ-1C547-A (ESP-M2C83-C) or equivalent and install it on the piston and ball nut. 2. Install a new Teflon piston seal on the piston and ball nut being careful not to stretch it more than necessary. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5367 Start-Up Procedure After Pump or Gear Service Upon initial engine start-up after a power steering pump or gear overhaul (particularly the pump), there is very frequently much noise and aeration. This is due to air trapped in the overhauled unit which mixes with the surging fluid and causes aeration. The problem can be minimized if the following procedure is used. 1. Disconnect ignition control module (ICM) connector to prevent engine from starting. 2. Fill the power steering oil reservoir. 3. Crank the engine with the starter motor and continue adding fluid until the level remains constant. Be careful to avoid prolonged cranking as the battery may be drained and the starter motor damaged. 4. Rotate the steering wheel approximately 30 degrees each side of center while continuing to crank the engine. 5. Recheck the fluid level and fill as required. 6. Reconnect the ICM connector. 7. To clear diagnostic trouble codes, disconnect battery for one minute and then reconnect battery. 8. Start the engine and allow it to run for several minutes. Rotate the steering wheel from stop to stop. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 9. Shut off the engine and recheck the fluid level. Add as required. Disassembly 1. Remove the snap ring from the lower end of the housing. 2. Remove dust seal using Puller Attachment 158L-1O1-B and Slide Hammer T59L-1OO-B or equivalent. 3. Remove pressure seal in the same manner. Discard the seal. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5368 Assembly 1. Lubricate the new pressure seal and dust seal with Ford Multi-Purpose Grease DOAZ-19584-AA (ESR-M1C159-A) or equivalent. 2. Apply Ford Multipurpose Grease DOAZ-19584-AA (ESR-M1C159-A) or equivalent to the sector shaft seal bore. 3.Place the dust seal on Sector Shaft Replacement Tool T77L-3576-A or equivalent, so the raised lip of the seal is towards the tool. 4. Place the pressure seal on the tool with lip away from the tool. The flat back side of the pressure seal should be against the flat side of the dust seal. 5. Insert the seal driver tool into the sector shaft bore and drive the tool until the seals clear the snap ring groove. Do not bottom seals against bearing. The seal will not function Properly when bottomed against the bearing. 6. Install snap ring in the groove in the housing. 7. Apply a generous amount of Ford Multi-Purpose Grease DOAZ- 19584-AA (ESR-M1C159-A) or equivalent, to the areas between the two seal lips. Disassembly 1. Remove the dust seal from the rear of the valve housing using Puller Attachment T58L-1O1-B, and Slide Hammer T59L-1O0-B. Discard the seal. 2. Remove the snap ring from the valve housing. 3. Turn the bench mounted holding fixture to invert valve housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5369 4. Insert Tool T65P-3524-A2 and T65P-3624-A3 from the Input Shaft Bearing seal Tool in the valve body assembly opposite the oil seal end and gently tap the bearing and seal out of the housing. Discard the seal. Do not damage the housing. when Inserting and removing the tool. 5. Remove the fluid inlet and outlet tube seats with Tube seat Remover T74P-35O4-L if they are damaged. Assembly 1. Coat the fluid inlet and outlet tube seats with petroleum jelly or equivalent and install them in the housing with a Tube Seat Installer T74P-3504-M. 2. Coat the bearing and seal surface of the housing with petroleum jelly or equivalent. 3. Install the bearing with the metal side covering the rollers facing outward. Seat the bearing in the valve housing using Tool T65P-3524-A1. Be sure the bearing rotates freely. 4. Dip a new oil seal in Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent and place it in the housing with the metal side facing outward. Drive the seal into the housing until the outer edge does not quite clear the snap ring groove. 5. Place the snap ring in the housing and drive on the ring using Tool T65P-3524-A1 until the snap ring seats in its groove. 6. Place the duet seal in the housing with the dished side (rubber side) facing out. Drive the dust seal into place using Tool T65P-3524-A1. When properly installed, the seal will be located behind the undercut in the input shaft. Apply a generous amount of Ford Multi-Purpose Grease DOAZ-19584-AA (ESR-M1C159-A) or equivalent to the area between the two seals. Disassembly Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5370 1. Remove valve sleeve seals from sleeve by inserting the blade of a small pocket knife under them and cutting them off. Assembly 1. Use the various tools from Seal Installation Set T75L-3517-A, during assembly. 2. Mount the worm end of the worm and valve sleeve assembly into a soft-jawed vise. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5371 3. Install Mandrel Tool T75L-3517-A1 from the Seal Installation Set over the sleeve, slide one valve sleeve ring over the tool. 4.Slide the pusher Tool T75L-3517-A2 over the mandrel, rapidly push down on the pusher tool, forcing the ring down the ramp and into the fourth groove of the valve sleeve. - Repeat this step three more times, and each time add one of the spacers T75L-3517-A3, under the mandrel tool. By adding a spacer each time, the mandrel tool will line up with the next groove of the valve sleeve. 5. After installing four valve sleeve rings, apply a light coat of Premium Power Steering Fluid, E6AZ-19582-AA (ESW-M2C33-F) or equivalent to the sleeve and rings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Removal > Page 5372 6. Install one spacer, T75L-3517-A3, over the input shaft as a pilot for installing the sizing tube. - Slowly install the sizing tube Tool T75L-3517-A4, over the sleeve valve end of the worm shaft onto the valve sleeve rings. Make sure that the rings are not being bent over as the tube is slid over them. - Allow the sizing tube to sit over the rings for five (5) minutes. 7. Remove the sizing tube and check the condition of the rings. Make sure that the rings turn freely in the grooves. NOTE: No further service or disassembly of the worm valve assembly is possible. Valve centering will be destroyed if disassembly is attempted. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. From underside of steering wheel, remove screws attaching horn pad to steering wheel spokes. 3. Lift up steering wheel pad, then disconnect horn wires and electrical connectors from pad. 4. Remove steering wheel attaching bolt and damper, if equipped. 5. Remove steering wheel using steering wheel remover T67L-3600-A or equivalent. CAUTION: Do not use a knock-off type wheel puller or strike end of steering shaft, as damage will result. INSTALLATION 1. Position steering wheel on end of steering shaft, aligning mark and flats on steering wheel with mark and flats on steering shaft, and ensure straight ahead steering wheel position corresponds with straight ahead position of front wheels. 2. If equipped, install damper and align locators with hole in wheel hub. 3. Install steering wheel attaching bolt and torque to 23-33 ft. lbs. 4. Connect horn wires and electrical connectors, then install horn pad. 5. Connect battery ground cable, then check steering column for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bracket Axle Beam: Service and Repair Axle Pivot Bracket 1. Remove front spring, radius arm, wheel spindle and I-beam. Fig. 11 Front I-beam axle assembly 4x2 Models. Ranger Fig. 14 Front I-beam axle assembly 4x2 Explorer 2. Remove four attaching nuts and two bolts and retainer assemblies. Remove axle pivot bracket, Fig. 5 through 6. 3. Reverse procedure to install. Position axle pivot bracket to frame and install forward and rearward bolts and retainer assemblies from inside of pivot bracket out through crossmember. Loosely install four nuts on outside of crossmember (two forward and two rearward). Torque nuts to 70-90 ft. lbs. Use nut N8802073-S2 or install one .20 inch thick hardened washer under each nut if a standard nut is used. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Service and Repair > Axle Pivot Bracket > Page 5381 Axle Beam: Service and Repair Axle Pivot Bushing REMOVAL AND INSTALLATION 1. Remove the front coil spring. 2. For left I-beam axle, remove axle pivot bolt and nut and pull left I-beam axle down until bushing is exposed. For right I-beam axle, entire right I-beam axle must be removed. Fig. 17 Axle Pivot Bushing Removal. 4x2 Models 3. Install forcing screw tool No. T78P-5638-A1, bushing remover tool No. T80T-5638-A2, spacer tool No. T82T-0.006-A4 and receiver cup tool No. T78P-5638-A3 onto pivot bushing or equivalents. Turn forcing screw and remove pivot bushing, Fig. 9. Fig. 18 Axle Pivot Bushing Installation. 4x2 Models 4. Reverse procedure to install. Refer to Fig. 10. Lower vehicle and tighten pivot bushing and nut to 120-150 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower Ball Joint: Testing and Inspection Ball Joint, Lower 1. Raise and support vehicle, then place safety stands under I-Beam axle beneath coil spring. 2. Grasp lower edge of tire and move wheel in and out, observe lower spindle arm and lower part of axle jaw. 3. If movement between lower spindle arm and lower spindle jaw is greater than 1/32 inch, replace lower ball joint. 4. Grasp upper edge of tire and move tire in and out, observe movement between upper spindle arm and upper part of axle jaw. 5. If movement is between upper part of axle jaw and upper spindle arm is greater than 1/32 inch, replace upper ball joint. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower > Page 5386 Ball Joint: Testing and Inspection Ball Joint, Upper 1. Raise and support vehicle, then place safety stands under I-Beam axle beneath coil spring. 2. Grasp lower edge of tire and move wheel in and out, observe lower spindle arm and lower part of axle jaw. 3. If movement between lower spindle arm and lower spindle jaw is greater than 1/32 inch, replace lower ball joint. 4. Grasp upper edge of tire and move tire in and out, observe movement between upper spindle arm and upper part of axle jaw. 5. If movement is between upper part of axle jaw and upper spindle arm is greater than 1/32 inch, replace upper ball joint. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower Fig. 6 Ball Joint Replacement. 4x2 Models 1. Remove spindle. Remove snap rings from ball joints, Fig. 11. 2. Assemble C-Frame tool No. T74P-4635-C and receiving cup tool No. D81T-3010-A or equivalents on upper ball joint. Turn forcing screw clockwise until ball joint is removed. Assemble C-Frame and cup on lower ball joint and turn forcing screw clockwise until ball joint is removed. NOTE: Always remove lower ball joint first. 3. Reverse procedure to install. Install lower ball joint first using ball joint receiver cup tool No. D81T-3010-A5 and installation cup tool No. D81T-3010-A1 inside adapter cup tool No. D81T-3010-A4 or equivalents. Turn forcing screw until ball joint is seated. Install snap ring onto lower ball joint. Install upper ball joint in same manner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 5389 Ball Joint: Service and Repair Ball Joint, Upper Fig. 6 Ball Joint Replacement. 4x2 Models 1. Remove spindle. Remove snap rings from ball joints, Fig. 11. 2. Assemble C-Frame tool No. T74P-4635-C and receiving cup tool No. D81T-0.010-A or equivalents on upper ball joint. Turn forcing screw clockwise until ball joint is removed. Assemble C-Frame and cup on lower ball joint and turn forcing screw clockwise until ball joint is removed. NOTE:Always remove lower ball joint first. 3. Reverse procedure to install. Install lower ball joint first using ball joint receiver cup tool No. D81T-3010-A5 and installation cup tool No. D81T-3010-A1 inside adapter cup tool No. D81T-3010-A4 or equivalents. Turn forcing screw until ball joint is seated. Install snap ring onto lower ball joint. Install upper ball joint in same manner. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Radius Arm Bushing > Component Information > Service and Repair Radius Arm Bushing: Service and Repair 1. Loosen axle pivot bolt and upper shock absorber pivot bolt and compress shock. Fig. 10 Radius Arm Replacement. 4x4 Models 2. Remove nut and washer attaching radius arm to radius arm bracket. Remove outer insulator and spacer, Fig. 20. 4. Move radius arm and axle assembly forward out of radius arm bracket. Remove inner insulator and retainer. 5. Reverse procedure to install. Tighten upper shock bolt, Disconnect stabilizer bar from front I-beam axle assembly, if equipped. 6. Remove axle to frame pivot bracket bolt and nut. Remove axle. 7. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair 1. Raise and support front of vehicle. Remove front wheel, then the brake caliper assembly. Support caliper with a length of wire. 2. Remove dust cap, cotter pin, nut retainer, nut, washer, outer bearing and rotor from spindle. 3. Remove inner bearing cone and seal, then the brake dust shield. Discard the seal. 4. Remove tie rod end, then disconnect steering linkage from spindle by removing cotter pin and nut. 5. Remove nut from upper ball joint stud, then the cotter pin and nut from lower ball joint stud. Ball Joint Service 6. Strike lower side of spindle to pop ball joints loose from spindle, Fig. 4, then remove the spindle. 7. Reverse procedure to install, noting the following: a. When installing ball joint stud nuts, coat studs with Loctite 242, or equivalent. b. Tighten upper ball joint attaching nuts to 27-37 ft lb and lower ball joint attaching nuts to 80-113 ft lb. c. Tighten steering linkage. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front Stabilizer Bar: Service and Repair Front Fig. 17 Front Stabilizer Bar Replacement 1. Remove stabilizer link assembly nut and washer, then disconnect stabilizer link assembly from front I-beam axle, Fig. 17. 2. Remove stabilizer bar attaching bolts, then the stabilizer bar retainers from the stabilizer bar assembly. 3. Remove stabilizer bar from vehicle. 4. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair > Front > Page 5401 Stabilizer Bar: Service and Repair Rear Fig. 8 Stabilizer Bar Replacement 1. Disconnect stabilizer bar from rear link, Fig. 11. 2. Remove mounting bracket U-bolt, then the mounting bracket, retainer and stabilizer bar. 3. Reverse procedure to install. The UP marking on the mounting bracket must be positioned as shown in Fig. 11. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation Suspension Spring ( Coil / Leaf ): Description and Operation Semi-elliptic leaf type rear springs are used for the rear axle suspension. The forward end of each rear spring is attached to a bracket on the frame side member. The rear end of each rear spring is shackled to a bracket on the frame side member Fig. 2 Rear Suspension The Explorer rear axle is mounted above the rear spring, Fig. 2. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Suspension Spring ( Coil / Leaf ): Service and Repair Rear 1. Raise rear of vehicle until weight is relieved from spring, with tires remaining in contact with floor. Fig. 5 Leaf Spring U-bolt Removal 2. Remove U-bolt nuts and the U-bolts, Fig. 8. Fig. 6 Forward Leaf Spring Mounting 3. Remove spring to bracket attaching nut and bolt, Fig. 9. Fig. 7 Rear Leaf Spring Mounting 4. Remove shackle to bracket attaching nuts and bolts, Fig. 10, then the spring and shackle assembly. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 5407 Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring 1. Raise and support front of vehicle. Support axle. Fig. 7 Coil Spring Replacement. 4x2 Models 2. Remove lower retainer nut and lower retainer, Fig. 12. Lower axle until it hangs unsupported. 3. Insert pry bar between axles and force appropriate I-beam axle down far enough to allow spring to be lifted over bolt in lower spring seat. Rotate spring until retainer on upper spring seat is cleared. Remove spring. NOTE:The axle must be supported when replacing spring and not be permitted to hang by the brake hose. If the length of the brake hose is not sufficient to permit spring replacement, it will be necessary to remove the disc brake caliper. Do not suspend caliper by brake hose, if removed. 4. Reverse procedure to install. Install bolt in axle arm and tighten nut all the way down. Install top of spring into upper spring seat and rotate into position. Raise axle until spring is seated in lower spring upper seat. Install lower retainer and nut. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber Fig. 4 Shock Absorber Replacement. 4x2 Models Fig. 5 Shock Absorber Replacement. 4x4 Models 1. Remove nut and washer from shock absorber at spring seat, Fig. 14 and 15. 2. Remove nut and bolt from shock absorber at radius arm and lower shock bracket. Slightly compress shock and remove. 3. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5412 Suspension Strut / Shock Absorber: Service and Repair Rear 1. Raise vehicle and support rear axle. 2. Remove lower attaching bolt and nut from shock absorber, then swing lower end free from mounting bracket. Fig. 4 Shock Absorber Replacement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5413 Fig. 6 Shock Absorber Replacement 3. Disconnect shock absorber from upper mounting, then remove shock from vehicle, Fig. 5 and 6. 4. Reverse procedure to install. Tighten shock absorber lower brkt. mounting bolts to 40-60 ft lb and the upper mounting bolts to 41-63 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5414 Suspension Strut / Shock Absorber: Service and Repair Rear Lateral NOTES: ^ Forward and rearward motion (relative movement between rubber shock bushing and metal sleeve) at each end of lateral shock is normal. Do not replace lateral shock if this condition exists. ^ Relative movement between the metal shock sleeve and the frame/axle brackets is not normal. If necessary, tighten frame end bolt to 39-53 ft. lbs. and axle end bolt to 50-68 ft. lbs. specifications. 1. Raise and support vehicle. 2. Support rear axle with suitable jack stand. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 5415 Fig. 7 Lateral Shock Absorber Replacement 3. Remove upper lateral shock mounting bolt and nut, Fig. 7. 4. Remove lower mounting bolt and nut. 5. Reverse procedure to install, noting the following: a. Install larger end of lateral shock to frame bracket. b. Tighten upper mounting bolts to 39-53 ft. lbs. and lower mounting bolts to 50-68 ft lb specifications. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments REMOVAL AND INSTALLATION 1. Raise and support front of vehicle. 2. Remove wheel cover, grease cap, cotter pin and locknut. 3. Loosen adjusting nut 3 turns, then lock wheel assembly in and out several times to push brake shoe and linings away from rotor. 4. Torque adjusting nut to 17-25 ft lb while rotating wheel assembly. 5. Loosen adjusting nut 1/2 turn, then retorque to 18-20 inch lbs. 6. Install locknut and cotter pin. 7. Ensure wheel assembly rotates smoothly, then reinstall grease cap and wheel cover and lower vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips Wheel Hub (Locking): Technical Service Bulletins Automatic Hublock - Diagnosis/Service Tips Article No. 95-5-18 03/13/95 ^ LOCK HUBS - 4WD - AUTOMATIC HUBLOCK INFORMATION - SERVICE TIPS ^ FOUR-WHEEL DRIVE (4WD) - AUTOMATIC LOCK HUB DIAGNOSIS LIGHT TRUCK: 1983-90 BRONCO II 1983-95 RANGER 1991-94 EXPLORER ISSUE: 4X4 system diagnosis can be difficult at times due to system complexities. ACTION: For general system operation and diagnosis: Refer to TSB Article No. 92-1-8. For specific automatic lock hub diagnosis and service: Refer to this article. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5423 HUBLOCK DIAGNOSTICS WHEEL END CONTAMINATION: ^ All compact vehicle hublocks have an O-ring seal between the hublock and wheel hub to prevent contamination. Whenever the hublock is removed, the 0-ring seal should be checked for damage. ^ If contamination is found in the wheel end, the path must be determined and corrected. Path possibilities are through the hublock seal, the wheel bearing seals or the axle spindle seals. WHEEL END NOISE (BUZZING) IN 4X2, AFTER UNLOCKING HUBS, SHORTLY AFTER FOUR-WHEEL DRIVE USAGE: ^ Noise concerns in two-wheel drive shortly after shifting from four-wheel drive and unlocking hubs, can occur if one of the hublocks fails to disengage. As the vehicle moves forward, the one (1) hublock that has failed to disengage will rotate its axle shaft through the differential and attempt to rotate the other axle shaft in the opposite direction. This is called differential motoring torque. As this torque attempts to turn the other axle shaft through the differential gears, that shaft's hublock will attempt to engage which will result in a ratcheting or buzzing noise. ^ This type of noise concern is usually found on axles that have incorrect front axle differential lubricant or very few 4X4 miles on them. ^ Verify that the front axle differential lubricant is F1TZ-19580-A. If incorrect lubricant is detected, extract the old lubricant using a suction gun. NOTE: BREAKING THE CARRIER SEAL IS NOT A RECOMMENDED METHOD OF EXTRACTING THE LUBRICANT. 1. Refill the front axle with 56 oz (1.66 L) of lubricant F1TZ-19580-A using a suction gun. 2. As the front axle accumulates 100-200 miles (161-322 km) of locked hublock operation, the axle will break-in, thus reducing the amount of differential motoring torque significantly. 3. If a front axle requires breaking in, refer to the Front Axle Break-In Procedure in this article. 4. If the front axle has been broken-in and the differential lubricant is F1TZ-19580-A, however, a wheel end noise (buzzing) in 4X2 is still experienced shortly after four-wheel drive usage. It is advised that the hublock which is not ratcheting be replaced as it is not disengaging correctly. When this condition occurs on any 4X4 Ranger, Explorer, or Bronco II, built from 10/89 through model year 1993, it is advised that both hublocks be replaced as the ratcheting hub is likely to become damaged. FRONT AXLE BREAK-IN PROCEDURE: ^ To break-in the front axle, engage four-wheel drive and then shift out of it without disengaging the hublocks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5424 ^ Thereafter, continue to drive the vehicle with locked hublocks until 100-200 miles (161-322 km) are accumulated. This will break-in the axle. Should the vehicle be backed up during this time period, the hublocks will disengage and will have to be locked again by repeating the engagement procedure. WHEEL END NOISE (RATCHETING) IN 4X2 AND HUBS UNLOCKED: ^ This condition could occur during turns or when the suspension is stroked. It is more prevalent in cold weather, with new front axles. It is usually caused by high motoring torque at the axle shafts or by incorrect axle lubrication. ^ Verify that axle lubrication is F1TZ-19580-A. If the front axle is not broken-in, 100-200 4X4 miles (161-322 km), proceed to do so following the outlined front axle break-in procedure in the Hublock Diagnostics section of this TSB article. WHEEL END NOISE (BUZZING) WHILE ENGAGING 4X4 (TOUCH DRIVE) WHILE MOVING: ^ Refer to TSB Article No. 91-15-10. POPPING/BANGING SOUND WHILE IN 4X4: ^ If the system slips under load, find what has broken or is slipping. To locate where slip is taking place, put marks at various possible slip points (Figure 1). Test drive the vehicle, then check to see if marks at different points are still in the same relationship to each other. This will help you determine where the slippage is taking place or where to look for broken parts, if any. ^ On vehicles with automatic hubs, find a place where you can do your test, mark the components, then drive without backing up. Stop and check the marks to see if they are in the same relationship to each other. If you back up before checking your marks, the hubs may reindex and not reveal the problem. ^ Reindex component should be serviced. INSTALLATION PROCEDURE 1. Remove old hublock; remove key from bearing retainer nut and then remove nut. 2. If replacing a manual hublock with an automatic hublock, also remove the three-piece wheel bearing nut assembly. 3. Remove the new wheel bearing retaining nut from the cam assembly and install on the threaded spindle. 4. Using Hex Locknut Wrench (T70T-4252-B), torque the wheel bearing retainer nut to 47 N-m (35 lb.ft.) while rotating the wheel assembly. Back nut off 1/4 turn and retighten to 1.8 N-m (16 lb.in.) of torque. 5. Align scallop of the wheel bearing retaining nut with the center of the spindle keyway by advancing the nut clockwise. 6. Install the retaining key into the spindle keyway. With the garter spring inboard, align the key on the cam assembly with the keyway on the spindle. 7. Firmly press the cam assembly on the wheel bearing retaining nut. CAUTION: DO NOT PACK THE HUBLOCK WITH GREASE. TOO MUCH GREASE WILL CAUSE IMPROPER HUBLOCK OPERATION AND MAY DAMAGE THE HUBLOCK. 8. For Ranger and Bronco II, model years 1983-90 (through build date 10/4/89), using the DANA 28 Axle, install the thrust washer set onto the axle: a. First, the plain steel washer. b. Second, the needle bearing. c. Last, the spline washer. 9. For model years 1990-94 (begin build date 10/5/89), DANA 35 Axle, install the one-piece spline washer. Install the "C" clip into the axle groove. It may be necessary to push the axle outboard from the inboard side of the knuckle. 10. For 1995 Ranger, install the thrust washer onto the axle: a. First, the plain steel thrust washer. b. Second, the plastic unsplined thrust washer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5425 c. Last, the steel spline thrust washer. CAUTION: ENSURE THE RETAINING RING OR "C" CLIP IS SEATED PROPERLY IN THE AXLE GROOVE FOR STEPS 8, 9, OR 10. 11. Check to ensure 0-ring seal on the flange face of the hublock body is not damaged and is properly positioned in its groove. 12. Install the hublock body assembly into the vehicle hub and rotor assembly. The hub may have to be rotated to line up the three (3) prongs of the cam follower (found internally to the hublock) with the cam assembly. 13. Install retainer flat nuts on wheel studs. NOTE: DO NOT FORCE THE HUBLOCK ASSEMBLY. IF THE BODY ASSEMBLY WILL NOT FIT, RECHECK THE ALIGNMENT OF ALL COMPONENTS. INSTALL SPEEDNUTS ON WHEEL LUGS TO RETAIN HUBLOCK. THEREAFTER, INSTALL THE WHEEL AND TORQUE THE LUG NUTS TO 136 N-m (100 LB.FT.) (FIGURE 2). HISTORY AND TIMING The Warn Automatic Hublock (Model M350) was used on the DANA 28 Axle (Bronco II and Ranger) from model years 1983-90 (through build date 10/4/89). The Warn Automatic Hublocks (Models M350A and M350B) were used on the DANA 35 Axle (Bronco II, Explorer and Ranger) for model years 1990-93 (begin build date 10/5/89). Starting with model year 1994 the Warn Automatic Hublock (Model M350C) used on the DANA 35 Axle (Explorer and Ranger) was introduced. The Model M350 is black and Model M350A, M350B and M350C are argent (white silver) in color. The Model M350 can only be replaced by Model M350 service parts. The M350C service kits should be used as replacements for the following: ^ M350A hublocks released 10/89 as model year 1990 running change. ^ M350B hublocks released 4/92 as model year 1992 late running change. ^ M350C hublocks released 8/93 as model year 1994 Job 1 change. When automatic hublock servicing is required for any Ranger, Explorer, or Bronco II built from 10/89 through model year 1993, it is advised that both hublocks be replaced. NOTE: IF AN M350A OR M350B HUBLOCK REQUIRES SERVICING, ALL THE HUBLOCK COMPONENTS MUST BE REMOVED AND REPLACED WITH SERVICE KIT F3TZ-3B396-B, WHICH ESSENTIALLY IS THE SERVICE KIT FOR THE M350C AUTOMATIC HUBLOCK. THE CAM ASSEMBLY OF THE M350A OR M35OB SHOULD NOT BE USED WITH AN M350C AUTOMATIC HUBLOCK BODY NOR SHOULD AN M350A OR M350B AUTOMATIC HUBLOCK BODY BE USED WITH AN M350C CAM ASSEMBLY. For model year 1994 (and beyond) 4X4 Rangers or Explorers, replace automatic hublocks in accordance with the automatic hublock Service Manual procedure and additional diagnostics procedure outlined in this TSB. IDENTIFYING AUTOMATIC HUBLOCK MODELS A stamped code found on the rear of the automatic hublock flange face can be used to identify the automatic hublock type, in addition to the model year summary described above. Examples of the three (3) different codes which correlate to the automatic hublock model type are outlined in the chart: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5426 THE ABOVE PART APPLICATION CHART IS FOR 1983-90 (THROUGH BUILD DATE 10/4/89) BRONCO II, RANGER, DANA 28 AXLE, HUBLOCK MODEL M350: THE ABOVE PART APPLICATION CHART IS FOR: ^ 1990-95 Ranger (begin build date 10/5/89) ^ 1990 Bronco (begin build date 10/5/89 through end of production) ^ 1991-94 Explorer (through build date 11/18/94, DANA 35 Axle, Hublock Model M350C) OTHER APPLICABLE ARTICLES: 92-1-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 508000, 509000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5436 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5437 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5438 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5439 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5440 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5441 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5442 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5443 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5444 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5445 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5450 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5451 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5452 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5453 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5454 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5455 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5456 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5461 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5462 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5463 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5464 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5465 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5466 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5467 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement Technical Service Bulletin # 01B77 Date: 011001 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5473 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5474 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5475 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5476 Attachment I - Administrative Information OASIS OASIS must be used to determine vehicle eligibility. IMPORTANT: When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund or tire replacement has already been processed on this vehicle. Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered under this program, but will not be active in OASIS. Contact the Special Service Support Center at 1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will insure that a previous repair/refund has not been performed on the vehicle. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5477 ^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.). ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires at a time. ^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. RELATED DAMAGE Vehicle damage caused by a tire related failure is not covered by this program. Refer to the Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year vehicles with alleged tire related vehicle damage should be handled through the Firestone claims process, or by referring the customers to their insurance company. Damage related to replacement of tires should be handled as described in the Warranty and Policy Manual. OWNER REFUND With the increased availability of replacement tires, it will no longer be necessary for customers to pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers who purchase tires prior to November 15, 2001. The following rules apply to refunds for tires purchased from August 1, 2001 through November 15, 2001: Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires installed. ^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on an exception basis in instances where the owner requires the original for another purpose (e.g. extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy of the refund claim (see claim instructions below). ^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming instructions for refunds and Attachment II for labor operations). ^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a refund (through October 31, 2001 for 1995 and 1996 F-150 owners). ^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001 must provide either: NOTE: This does not apply to 1995 and 1996 F-150 customers. ^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not process the refund. ^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If sections are brought in for refund with the DOT code defaced dealers should not process the refund. NOTE: The DOT Code Identification Guide has been developed to help dealers determine if the DOT sections returned to the dealership are from 15-, 16-, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5478 or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to determine how many tires are eligible for refund. NOTE: Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22 through June 30, 2001 because customers may not have tires to turn in. Customers must provide a paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or DOT sections. Ford will reimburse customers the following amounts: ^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. ^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31, 2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes. No DOT section required. ^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires. ^ Refunds will not be granted for tires purchased after November 15, 2001. Note: If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle on a case by case basis following the procedure in Attachment II. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5479 CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND REQUESTS) NOTE: Tires must be purchased prior to November 15, 2001 ^ Enter claims using DWE. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type. ^ Program code 01B77. ^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G (disable) and 01B77L (refund administration allowance) from Attachment II. ^ If a customer brings in the old DOT codes removed from the old tires - use labor operation 01B77L only. ^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor operation 01B77L has been provided to cover administrative costs. ^ Enter REFUND in the miscellaneous area of the claim. ^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER in the expense area of the claim with the actual cost. ^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the space provided in the diagnostic code area, use the technician comment area to complete the data entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996 F150 customers) the DOT may not be available, in this case record the brand, make and size of the tires in the technician comments area of the claim. RENTAL CARS TAP allowances have been increased specifically for this owner notification program. Refer to Don Brunner letter. DOT REGISTRATION OF NEW TIRES Dealers are required to register the DOT number of every tire sold to meet federal tire registration requirements. Ford has established a partnership with CIMS to assist dealers in registering these DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by contacting CIMS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5480 at 330-794-9190. NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE, with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair type. Attachment II - Parts and Labor Information LABOR ALLOWANCES NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES NOTE: Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation. PARTS REQUIREMENTS Tire Ordering Information ^ Dealers are required to install only tires from the Approved Tire List for vehicles originally equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately order replacement tires for inventory. ^ Certified Tire Dealers will order replacement tires through normal channels. ^ Dealers not authorized for the Around the Wheel Program will not participate in this recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. TIRE AVAILABILITY: All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the following to ensure that you are able to secure your fair allotment of these limited volumes: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5481 ^ Contact your Ford authorized facing distributor(s) for each tire manufacturer. ^ Contact your Ford authorized facing tire retailers for each tire manufacturer. ^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill orders with every supply point. Questions not addressed by above sources should be directed to your market area team. CUSTOMER WAIT LISTS: Dealers should create a customer wait list and record: Customer name ^ Address and phone number ^ Vehicle make ^ Model year ^ Mileage ^ Tire size NOTE: Customers should be prioritized to replace oldest tires first. WAIT LIST SURVEY Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It is critical that you answer the questions as accurately as possible as the survey results will be used to help determine the level of production from the tire manufacturers. DEALER PRICE For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List. PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15, 2001 The following procedure applies to tires purchased after November 15, 2001: 1. Determine if the customer should receive special consideration based on owner loyalty, special circumstance cc, etc. 2. If the customer is eligible for special consideration the dealer will call the Special Service Support Center at 1800-325-5621 to request an authorization code. 3. The Special Service Support Center representative will ask for the following: ^ Customer Name ^ VIN ^ Date of repair ^ Original copy of invoice (be prepared to fax) 4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer with an authorization code. 5. Your dealer will input a claim with the authorization code (authorization code must be included to receive payment). 6. After the dealer receives payment for the claim, the dealer will then send the refund to the customer. NOTE: If the Special Service Support Center determines that the customer does not qualify for a refund, no authorization code will be given. Any appeals must be made by the dealer to the appropriate field representative Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 5482 AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES OVERVIEW This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires regardless of production plant. You will need to perform a DOT code inspection prior to replacing the 15, 16, or 17-inch Wilderness AT tires. NOTE: When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet when the tire is completely stowed. NOTE: Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not be replaced as part of this program. NOTE: Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may not store in the proper position on the vehicle. INSPECTION 1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT tires. 2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the "Approved Tire List". Note: There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT tire sizes that are not included on the Ford-approved replacement list. These tires are not original equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is recommended that the customer install the proper OE tire, or have a tire of suitable quality installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company Tire Price Guide" for OE or suitable replacement recommendations. 3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness AT you would not automatically replace all four (4) tires instead, you would replace the two (2) Wilderness AT tires and place them on the same axle. 4. Record the DOT code from each removed tire(s) on the repair order. 5. Tires that are removed from vehicles must immediately be made unusable by either cutting through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. 6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening. NOTE: Tires that are removed from vehicles under this program, and those in dealer inventory must immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT code will prevent the tire from being used for an additional refund request. NOTE: If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the replacement tires for the Firestone equipped axle causes a mismatch with the existing non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to purchase matching tires to correct the mismatch - the dealer should annotate the repair order to reflect the customer's decision. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label Technical Service Bulletin # 00L09 Date: 000910 Information 00L09 SPECIAL FIELD ACTION Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Explorer/Mountaineer & Explorer 2-Door Sport owner letter 2001 Explorer Sport Trac owner letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5487 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5488 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5489 LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels The supplemental tire inflation labels for this program are being sent directly to customers of the affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621. Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide your name, address, dealer P & A code, and vehicle(s) you need label(s) for. NOTE: There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991 through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear. Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear. DEALER PRICE Dealers will not be charged for the supplemental safety certification labels ordered under this program. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND 2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES. SERVICE PROCEDURE 1. Open the driver's door and clean the area of the door below the certification label using isopropyl alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if necessary. If any other permanent label is in this location, clean an area large enough to allow for full adhesion of the label to the painted door surface as close to the certification label as possible. 2. Allow the area to dry. 3. Peel the backing off the new supplemental certification label and install it per the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5490 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5491 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5492 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 5493 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall Technical Service Bulletin # FIRESTONE Date: 000901 Dealer Letter TO: All Ford and Lincoln Mercury Dealers SUBJECT: DEMONSTRATION / DELIVERY HOLD - Firestone Tire Recall: Certain 1991 through 2000 Explorer, 1997 through 2000 Mountaineer, 2001 MY Explorer Sport Trac and Sport, 1991 through 2000 Ranger, 1991 through 1994 Bronco and 1991 through 1994 F-Series - Replacement of Firestone P235/75 R15 Radial ATX and Certain Wilderness AT Tires. REFERENCE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5498 Firestone Recall - Firestone P235/75 R15 Radial ATX and Certain Wilderness AT tires. AFFECTED TIRES AND VEHICLES Bridgestone Firestone Tire Company recently announced a Safety Recall on the following: - All Firestone P235/75 R15 Radial ATX tires produced excluding tires marked "TEMPORARY" on the sidewall - and - P235/75 R15 wilderness AT tires produced only at the Decatur plant. NOTE: Decatur built tires have a DOT code of VDHL - see Attachment III for details. All other Wilderness AT tires are not affected. Both original equipment (OE) and replacement tires are affected. The following vehicles produced with Firestone P235/75 R15 Radial ATX original equipment tires are affected by this recall: ^ Certain 1991 through 1996 Ford Explorer (see chart) ^ Certain 1997 Mercury Mountaineer vehicles ^ Certain 1991 through 2000 Ranger vehicles ^ Certain 1991 through 1994 Bronco vehicles ^ Certain 1991 through 1994 F-Series vehicles The following vehicles produced with P235/75 R15 Wilderness AT tires as original equipment are affected by this recall: Certain 1997 through August 7, 2000 Mountaineer vehicles ^ Certain 1997 through August 7, 2000 Explorer vehicles (see chart) ^ Certain 1997 through June 1, 2000 Ranger vehicles ^ Certain 2001 Explorer Sport Trac and Sport vehicles produced through August 7, 2000 These Explorer vehicles produced with either P235/75 R15 Radial ATX or P235/75 R15 Wilderness AT tires as original equipment are affected as shown. These Explorer vehicles are NOT affected: IMPORTANT FACTS ^ This is a FIRESTONE recall. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5499 ^ FIRESTONE will notify customers of the recall via first class mail. ^ FIRESTONE will communicate recall information to authorized repair sites including Ford and Lincoln-Mercury Around the wheel/Ford Tire Program dealers. FORD AND LINCOLN MERCURY DEALER INVOLVEMENT As this field action will severely impact the availability of Firestone replacement tires, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers will be afforded the opportunity to address this recall utilizing Firestone and non-Firestone tires. This is being done to address immediate needs of our customers. FORD AND LINCOLN MERCURY DEALERS ENROLLED IN AROUND THE WHEEL (AtW) Dealerships enrolled in the AtW/Ford Tire Program are authorized Firestone outlets. If a customer with affected tires contacts an ATW Ford Tire Program dealer, as an authorized Firestone dealer regarding this safety recall, you will be able to replace that customer's tires with Firestone or "approved" non-Firestone tires. Tires that are approved for use as replacement tires under this recall will be posted in a matrix in the Firestone Tire Center in QCDealer.com. This matrix will be amended to add new tire manufactures and models of tires as they are approved. Claiming for reimbursement of tires is outlined on Attachment I. If the customer requests a replacement Firestone tire, secure the tire through your normal distribution chain and process reimbursement as outlined in Attachment I. FORD AND LINCOLN MERCURY DEALERS NOT ENROLLED IN AROUND THE WHEEL (AtW) Dealers not enrolled in the ATW/Ford Tire Program can inspect customer vehicles (see Attachments I & II for claiming instructions & labor operations). These dealers should make individual arrangements with local Firestone outlets for tire replacement, or refer customers to their local Firestone outlet. SERVICE PROCEDURE All Firestone P235/75 R15 tires with Radial ATX on the sidewall (excludes Temporary spare tires identified by "Temporary" on the sidewall) must be replaced under this recall. Firestone P235/75 R15 tires with Wilderness AT on the sidewall will need to be inspected for a DOT code of VDHL to determine if replacement is required. Refer to Attachment III for details. This service action applies to original equipment and replacement tires that are installed on Ford and Mercury vehicles. DEMONSTRATION / DELIVERY HOLD FOR VEHICLES AND TIRES IN DEALER INVENTORY Do not demonstrate or deliver any of the affected vehicles prior to completing the Firestone recall. In addition, Ford and Lincoln Mercury Around the Wheel (AtW)/Ford Tire Program dealers may have affected tires in inventory; these tires should not be sold. Tires Removed from Vehicles Tires that are removed from vehicles must immediately be made unusable by either cutting the bead with bolt cutters, drilling a one-inch diameter hole in the sidewall, or cutting the tire completely in half The DOT code should not be defaced or removed. The tire should then be disposed of according to local laws refer to the Tire Administration Guide for further information. NOTE: AtW/Ford Tire Program dealers will be independently audited for compliance with the above procedure. New Inventory Tires All new Radial ATX or Wilderness AT tires with DOT code VDHL tires (never mounted) in AtW/Ford Tire Program dealer inventory must be returned to Firestone. Dealers must call 1-800-668-0345 to obtain a "Returned Goods Authorization (RGA) number. The RGA is a 6-digit number required to return the tires. Only tires affected by the Firestone recall will be accepted. Firestone will pay all freight for the return of these tires. ATTACHMENTS ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5500 ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Attachment IV ^ Tire Inspection Aid ^ Attachment V ^ Tire Inflation Guide CONTACTS Claims Information: 1-800-423-8851 Other (Dealer Only) Recall Questions: 1-800-325-5621 For Around the Wheel/Ford Tire Program 1-888-353-3251 Questions: Attachment I OASIS Since this is a Firestone recall, OASIS will not be activated. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. CLAIMS PREPARATION AND SUBMISSION NOTE: Claims for Firestone tires (P18) may be entered for payment beginning with repairs dated August 28, 2000 and later. Claims for non-Firestone tires Enter claims in ACES II for non-Firestone tires using DWE with the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim. ^ Refer to ACESII User Manual for claims preparation and submission information. ^ Program Code - P17. Enter P17TIRE as the causal part with condition code 82. ^ On the same line as PI7TIRE enter the total value of the tires from the "Suggested List Price" column of the latest Ford Motor Company Tire Selling Guide. ^ Use the appropriate labor operation(s) from Attachment II. ^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim. NOTE: Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them shipped in via common carrier. ^ Tire disposal and applicable local waste tax will be reimbursed - enter OTHER in the miscellaneous expense area of the claim with the actual cost. ^ Enter the entire DOT code and the part number of the replacement tire being used in the comments area of the claim. Claims for Firestone tires Enter claims in ACES II for Firestone tires using the following information: ^ Enter information on a warranty claim. DO NOT use a recall claim type. ^ Program Code - P18. ^ Enter "P18TIRE" as the causal part, no material cost should be entered on this line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5501 ^ Condition code "82". ^ Use Customer Concern Code "A99". ^ Enter the full published tire part number with the quantity of tires replaced, the payment system will price the tire at Dealer Net multiplied by the quantity for the total value of the replaced tires. ^ Use Miscellaneous Expense Code "TIREMU" to claim the $20.00 difference per tire7 a maximum of $100.00. ^ The Firestone warranty claim form must be filled out and attached to the hard copy of the claim and retained in the service file. The entire DOT code from the replacement tire(s) must be recorded on this form. ^ The DOT code must also be entered in the comments area of the claim. ^ No labor operations will be allowed when claiming P18. OWNER REFUND Ford and Lincoln Mercury dealers, including AtW/Ford tire dealers; will not be involved in processing refunds for customers included in the Firestone recall. Customers inquiring about a refund should be provided copies of the Firestone refund request form. Refer to the Firestone website for the refund forms and for further details. RENTAL CARS TAP allowances have been increased specifically for the Firestone recall refer to M.J. Lombardi's Letter. Attachment II LABOR ALLOWANCES NOTE: Front-end alignment is not included in this recall. NOTE: These labor operations and revised times will begin paying with claims submitted on August 18, 2000; Claims in process at dealerships will need to use these new operations. PARTS REQUIREMENTS Tire Ordering Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5502 Authorized Around the Wheel (ATW)/Ford Tire Program dealers will order replacement tires through normal channels. Dealers not authorized for the Around the Wheel Program will not participate in the Firestone recall. Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details. DEALER PRICE For latest prices on replacement tires refer to the most recent Ford Motor Company Tire Selling Guide. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5503 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > FIRESTONE > Sep > 00 > Recall - Firestone Tire Recall > Page 5504 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments REMOVAL AND INSTALLATION 1. Raise and support front of vehicle. 2. Remove wheel cover, grease cap, cotter pin and locknut. 3. Loosen adjusting nut 3 turns, then lock wheel assembly in and out several times to push brake shoe and linings away from rotor. 4. Torque adjusting nut to 17-25 ft lb while rotating wheel assembly. 5. Loosen adjusting nut 1/2 turn, then retorque to 18-20 inch lbs. 6. Install locknut and cotter pin. 7. Ensure wheel assembly rotates smoothly, then reinstall grease cap and wheel cover and lower vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips Wheel Hub (Locking): Technical Service Bulletins Automatic Hublock - Diagnosis/Service Tips Article No. 95-5-18 03/13/95 ^ LOCK HUBS - 4WD - AUTOMATIC HUBLOCK INFORMATION - SERVICE TIPS ^ FOUR-WHEEL DRIVE (4WD) - AUTOMATIC LOCK HUB DIAGNOSIS LIGHT TRUCK: 1983-90 BRONCO II 1983-95 RANGER 1991-94 EXPLORER ISSUE: 4X4 system diagnosis can be difficult at times due to system complexities. ACTION: For general system operation and diagnosis: Refer to TSB Article No. 92-1-8. For specific automatic lock hub diagnosis and service: Refer to this article. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5512 HUBLOCK DIAGNOSTICS WHEEL END CONTAMINATION: ^ All compact vehicle hublocks have an O-ring seal between the hublock and wheel hub to prevent contamination. Whenever the hublock is removed, the 0-ring seal should be checked for damage. ^ If contamination is found in the wheel end, the path must be determined and corrected. Path possibilities are through the hublock seal, the wheel bearing seals or the axle spindle seals. WHEEL END NOISE (BUZZING) IN 4X2, AFTER UNLOCKING HUBS, SHORTLY AFTER FOUR-WHEEL DRIVE USAGE: ^ Noise concerns in two-wheel drive shortly after shifting from four-wheel drive and unlocking hubs, can occur if one of the hublocks fails to disengage. As the vehicle moves forward, the one (1) hublock that has failed to disengage will rotate its axle shaft through the differential and attempt to rotate the other axle shaft in the opposite direction. This is called differential motoring torque. As this torque attempts to turn the other axle shaft through the differential gears, that shaft's hublock will attempt to engage which will result in a ratcheting or buzzing noise. ^ This type of noise concern is usually found on axles that have incorrect front axle differential lubricant or very few 4X4 miles on them. ^ Verify that the front axle differential lubricant is F1TZ-19580-A. If incorrect lubricant is detected, extract the old lubricant using a suction gun. NOTE: BREAKING THE CARRIER SEAL IS NOT A RECOMMENDED METHOD OF EXTRACTING THE LUBRICANT. 1. Refill the front axle with 56 oz (1.66 L) of lubricant F1TZ-19580-A using a suction gun. 2. As the front axle accumulates 100-200 miles (161-322 km) of locked hublock operation, the axle will break-in, thus reducing the amount of differential motoring torque significantly. 3. If a front axle requires breaking in, refer to the Front Axle Break-In Procedure in this article. 4. If the front axle has been broken-in and the differential lubricant is F1TZ-19580-A, however, a wheel end noise (buzzing) in 4X2 is still experienced shortly after four-wheel drive usage. It is advised that the hublock which is not ratcheting be replaced as it is not disengaging correctly. When this condition occurs on any 4X4 Ranger, Explorer, or Bronco II, built from 10/89 through model year 1993, it is advised that both hublocks be replaced as the ratcheting hub is likely to become damaged. FRONT AXLE BREAK-IN PROCEDURE: ^ To break-in the front axle, engage four-wheel drive and then shift out of it without disengaging the hublocks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5513 ^ Thereafter, continue to drive the vehicle with locked hublocks until 100-200 miles (161-322 km) are accumulated. This will break-in the axle. Should the vehicle be backed up during this time period, the hublocks will disengage and will have to be locked again by repeating the engagement procedure. WHEEL END NOISE (RATCHETING) IN 4X2 AND HUBS UNLOCKED: ^ This condition could occur during turns or when the suspension is stroked. It is more prevalent in cold weather, with new front axles. It is usually caused by high motoring torque at the axle shafts or by incorrect axle lubrication. ^ Verify that axle lubrication is F1TZ-19580-A. If the front axle is not broken-in, 100-200 4X4 miles (161-322 km), proceed to do so following the outlined front axle break-in procedure in the Hublock Diagnostics section of this TSB article. WHEEL END NOISE (BUZZING) WHILE ENGAGING 4X4 (TOUCH DRIVE) WHILE MOVING: ^ Refer to TSB Article No. 91-15-10. POPPING/BANGING SOUND WHILE IN 4X4: ^ If the system slips under load, find what has broken or is slipping. To locate where slip is taking place, put marks at various possible slip points (Figure 1). Test drive the vehicle, then check to see if marks at different points are still in the same relationship to each other. This will help you determine where the slippage is taking place or where to look for broken parts, if any. ^ On vehicles with automatic hubs, find a place where you can do your test, mark the components, then drive without backing up. Stop and check the marks to see if they are in the same relationship to each other. If you back up before checking your marks, the hubs may reindex and not reveal the problem. ^ Reindex component should be serviced. INSTALLATION PROCEDURE 1. Remove old hublock; remove key from bearing retainer nut and then remove nut. 2. If replacing a manual hublock with an automatic hublock, also remove the three-piece wheel bearing nut assembly. 3. Remove the new wheel bearing retaining nut from the cam assembly and install on the threaded spindle. 4. Using Hex Locknut Wrench (T70T-4252-B), torque the wheel bearing retainer nut to 47 N-m (35 lb.ft.) while rotating the wheel assembly. Back nut off 1/4 turn and retighten to 1.8 N-m (16 lb.in.) of torque. 5. Align scallop of the wheel bearing retaining nut with the center of the spindle keyway by advancing the nut clockwise. 6. Install the retaining key into the spindle keyway. With the garter spring inboard, align the key on the cam assembly with the keyway on the spindle. 7. Firmly press the cam assembly on the wheel bearing retaining nut. CAUTION: DO NOT PACK THE HUBLOCK WITH GREASE. TOO MUCH GREASE WILL CAUSE IMPROPER HUBLOCK OPERATION AND MAY DAMAGE THE HUBLOCK. 8. For Ranger and Bronco II, model years 1983-90 (through build date 10/4/89), using the DANA 28 Axle, install the thrust washer set onto the axle: a. First, the plain steel washer. b. Second, the needle bearing. c. Last, the spline washer. 9. For model years 1990-94 (begin build date 10/5/89), DANA 35 Axle, install the one-piece spline washer. Install the "C" clip into the axle groove. It may be necessary to push the axle outboard from the inboard side of the knuckle. 10. For 1995 Ranger, install the thrust washer onto the axle: a. First, the plain steel thrust washer. b. Second, the plastic unsplined thrust washer. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5514 c. Last, the steel spline thrust washer. CAUTION: ENSURE THE RETAINING RING OR "C" CLIP IS SEATED PROPERLY IN THE AXLE GROOVE FOR STEPS 8, 9, OR 10. 11. Check to ensure 0-ring seal on the flange face of the hublock body is not damaged and is properly positioned in its groove. 12. Install the hublock body assembly into the vehicle hub and rotor assembly. The hub may have to be rotated to line up the three (3) prongs of the cam follower (found internally to the hublock) with the cam assembly. 13. Install retainer flat nuts on wheel studs. NOTE: DO NOT FORCE THE HUBLOCK ASSEMBLY. IF THE BODY ASSEMBLY WILL NOT FIT, RECHECK THE ALIGNMENT OF ALL COMPONENTS. INSTALL SPEEDNUTS ON WHEEL LUGS TO RETAIN HUBLOCK. THEREAFTER, INSTALL THE WHEEL AND TORQUE THE LUG NUTS TO 136 N-m (100 LB.FT.) (FIGURE 2). HISTORY AND TIMING The Warn Automatic Hublock (Model M350) was used on the DANA 28 Axle (Bronco II and Ranger) from model years 1983-90 (through build date 10/4/89). The Warn Automatic Hublocks (Models M350A and M350B) were used on the DANA 35 Axle (Bronco II, Explorer and Ranger) for model years 1990-93 (begin build date 10/5/89). Starting with model year 1994 the Warn Automatic Hublock (Model M350C) used on the DANA 35 Axle (Explorer and Ranger) was introduced. The Model M350 is black and Model M350A, M350B and M350C are argent (white silver) in color. The Model M350 can only be replaced by Model M350 service parts. The M350C service kits should be used as replacements for the following: ^ M350A hublocks released 10/89 as model year 1990 running change. ^ M350B hublocks released 4/92 as model year 1992 late running change. ^ M350C hublocks released 8/93 as model year 1994 Job 1 change. When automatic hublock servicing is required for any Ranger, Explorer, or Bronco II built from 10/89 through model year 1993, it is advised that both hublocks be replaced. NOTE: IF AN M350A OR M350B HUBLOCK REQUIRES SERVICING, ALL THE HUBLOCK COMPONENTS MUST BE REMOVED AND REPLACED WITH SERVICE KIT F3TZ-3B396-B, WHICH ESSENTIALLY IS THE SERVICE KIT FOR THE M350C AUTOMATIC HUBLOCK. THE CAM ASSEMBLY OF THE M350A OR M35OB SHOULD NOT BE USED WITH AN M350C AUTOMATIC HUBLOCK BODY NOR SHOULD AN M350A OR M350B AUTOMATIC HUBLOCK BODY BE USED WITH AN M350C CAM ASSEMBLY. For model year 1994 (and beyond) 4X4 Rangers or Explorers, replace automatic hublocks in accordance with the automatic hublock Service Manual procedure and additional diagnostics procedure outlined in this TSB. IDENTIFYING AUTOMATIC HUBLOCK MODELS A stamped code found on the rear of the automatic hublock flange face can be used to identify the automatic hublock type, in addition to the model year summary described above. Examples of the three (3) different codes which correlate to the automatic hublock model type are outlined in the chart: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Automatic Hublock - Diagnosis/Service Tips > Page 5515 THE ABOVE PART APPLICATION CHART IS FOR 1983-90 (THROUGH BUILD DATE 10/4/89) BRONCO II, RANGER, DANA 28 AXLE, HUBLOCK MODEL M350: THE ABOVE PART APPLICATION CHART IS FOR: ^ 1990-95 Ranger (begin build date 10/5/89) ^ 1990 Bronco (begin build date 10/5/89 through end of production) ^ 1991-94 Explorer (through build date 11/18/94, DANA 35 Axle, Hublock Model M350C) OTHER APPLICABLE ARTICLES: 92-1-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 508000, 509000, 590000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5520 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 5521 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 94815 > Apr > 94 > Climate Control - Vibration Type Sound Air Door Actuator / Motor: Customer Interest Climate Control - Vibration Type Sound Article No. 94-8-15 ^ CLIMATE CONTROL - LOOSE SPRING IN RECIRC DOOR VACUUM MOTOR MAKES VIBRATION NOISE - VEHICLES BUILT BEFORE 1/16/94 ^ NOISE - "VIBRATION TYPE" SOUND FROM LOOSE SPRING IN RECIRC DOOR VACUUM MOTOR - VEHICLES BUILT BEFORE 1/16/94 LIGHT TRUCK: 1991-94 EXPLORER, RANGER ISSUE: A vibration noise from under the dash may be heard while driving. This occurs because of a loose spring in the recirc door vacuum motor. ACTION: Install a revised recirc door vacuum motor which retains the spring. Refer to the appropriate model year Service Manual, Section 12, for the removal and installation details. PART NUMBER PART NAME CLASS F4TZ-18A318-A Recirc Door Vacuum Motor A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940815A Replace Recirculation Door 0.3 Hr. Vacuum Motor DEALER CODING BASIC PART NO. CONDITION CODE 18A318 56 OASIS CODES: 208000, 208300, 208999, 702000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 94815 > Apr > 94 > Climate Control - Vibration Type Sound Air Door Actuator / Motor: All Technical Service Bulletins Climate Control - Vibration Type Sound Article No. 94-8-15 ^ CLIMATE CONTROL - LOOSE SPRING IN RECIRC DOOR VACUUM MOTOR MAKES VIBRATION NOISE - VEHICLES BUILT BEFORE 1/16/94 ^ NOISE - "VIBRATION TYPE" SOUND FROM LOOSE SPRING IN RECIRC DOOR VACUUM MOTOR - VEHICLES BUILT BEFORE 1/16/94 LIGHT TRUCK: 1991-94 EXPLORER, RANGER ISSUE: A vibration noise from under the dash may be heard while driving. This occurs because of a loose spring in the recirc door vacuum motor. ACTION: Install a revised recirc door vacuum motor which retains the spring. Refer to the appropriate model year Service Manual, Section 12, for the removal and installation details. PART NUMBER PART NAME CLASS F4TZ-18A318-A Recirc Door Vacuum Motor A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage For 1992-94 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940815A Replace Recirculation Door 0.3 Hr. Vacuum Motor DEALER CODING BASIC PART NO. CONDITION CODE 18A318 56 OASIS CODES: 208000, 208300, 208999, 702000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 5537 Air Door Actuator / Motor: Service and Repair Vacuum Motor Removal 1. Open the glove compartment and remove contents. Push inward on the sides of the compartment and pull rearward until it disengages from its latched position and hangs down. The vacuum motor should be visible on the right side of the plenum. 2. Disconnect the vacuum hose from the vacuum motor nipple. 3. Remove the two screws which attach the vacuum motor to the plenum. 4. Swing the vacuum motor rearward and disconnect its arm from the shaft on the plenum by sliding the motor arm to the left. Installation 1. Position the vacuum arm so that the shaft on the plenum protrudes through the hole in the arm. 2. Swing the vacuum motor forward and install two screws to attach the motor to the plenum. 3. Connect the vacuum hose to the vacuum motor nipple. 4. Push the sides of the glove compartment inward and install it into its latched position. 5. Start the engine and verify that the vacuum motor responds properly to the function control lever when it is moved from its OFF position to one of the functional settings. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations Ambient Temperature Sensor: Locations Limited Edition And Electronic Group The Ambient Temperature Sensor is located at the left front of engine compartment, in front of radiator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations > Page 5541 Ambient Temperature Sensor: Description and Operation PURPOSE The Ambient Temperature Sensor is used by the air conditioning system to determine the outside air temperature. OPERATION The Ambient Temperature Sensor sends a signal to overhead console to indicate outside air temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise Blower Motor: Customer Interest Blower Motor - Burning Odor/Smoke/Rustling Noise Article No. 99-20-6 10/04/99 ^ AIR CONDITIONING - BURNING ODOR OR SMOKE WHILE BLOWER MOTOR IS ON ^ NOISE - "RUSTLING" HEARD ALONG WITH AN ODOR WHILE BLOWER MOTOR IS ON FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER This TSB article is being republished in its entirety to change the Causal Part number. ISSUE A burning odor or smoke, and/or "rustling" noise may occur when the blower motor is running if leaves or foreign material enter the blower case. Noise complaints may result from debris coming in contact with the blower fan. In some cases, the debris may also come in contact with the blower motor resistor which may be hot enough to cause a burning odor or smoke. ACTION Clean the debris out of the blower case and install foam grommets around the wiper pivots to seal out further debris from entering the system. Refer to the following Service Procedure for details. SERVICE PROCEDURE ALL MODEL YEARS - CLEAN DEBRIS FROM THE HEATER CASE 1. Remove blower motor (refer to the appropriate Service or Workshop Manual for procedure). 2. Remove blower motor resistor. NOTE BE CAREFUL NOT TO DAMAGE OR BEND RESISTOR COILS WHICH COULD RESULT IN AN ELECTRICAL SHORT. 3. Clean the blower motor, motor cooling tube, blower housing, resistor, and inlet duct of all debris. 4. Reinstall resistor. 5. Reinstall blower motor. 1991-1994 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5550 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5551 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise Blower Motor: All Technical Service Bulletins Blower Motor - Burning Odor/Smoke/Rustling Noise Article No. 99-20-6 10/04/99 ^ AIR CONDITIONING - BURNING ODOR OR SMOKE WHILE BLOWER MOTOR IS ON ^ NOISE - "RUSTLING" HEARD ALONG WITH AN ODOR WHILE BLOWER MOTOR IS ON FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER This TSB article is being republished in its entirety to change the Causal Part number. ISSUE A burning odor or smoke, and/or "rustling" noise may occur when the blower motor is running if leaves or foreign material enter the blower case. Noise complaints may result from debris coming in contact with the blower fan. In some cases, the debris may also come in contact with the blower motor resistor which may be hot enough to cause a burning odor or smoke. ACTION Clean the debris out of the blower case and install foam grommets around the wiper pivots to seal out further debris from entering the system. Refer to the following Service Procedure for details. SERVICE PROCEDURE ALL MODEL YEARS - CLEAN DEBRIS FROM THE HEATER CASE 1. Remove blower motor (refer to the appropriate Service or Workshop Manual for procedure). 2. Remove blower motor resistor. NOTE BE CAREFUL NOT TO DAMAGE OR BEND RESISTOR COILS WHICH COULD RESULT IN AN ELECTRICAL SHORT. 3. Clean the blower motor, motor cooling tube, blower housing, resistor, and inlet duct of all debris. 4. Reinstall resistor. 5. Reinstall blower motor. 1991-1994 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5557 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5558 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5559 Blower Motor: Locations Component Locations The Blower Motor is located at RH side of engine compartment, in blower housing. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5560 Blower Motor: Service and Repair 1. Disconnect battery ground cable. 2. Remove air cleaner in front of blower motor, if required. 3. On models with A/C, remove solenoid box cover, if equipped. 4. Disconnect electrical connector from blower motor. 5. Disconnect blower motor cooling tube at blower motor. Fig. 10 Blower Motor Replacement Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 5561 6. Remove blower motor attaching screws, position cooling tube aside, then pull blower motor from the heater blower assembly. 7. Reverse procedure to install, checking system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Box The Blower Motor Relay is mounted in the power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 5565 Blower Motor Relay: Description and Operation PURPOSE To provide current to operate the heater-A/C blower motor. OPERATION When the Blower Motor Relay is energized, relay contact closes and completes circuit for blower motor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Blower Motor Resistor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 5569 Blower Motor Resistor: Description and Operation PURPOSE To provide multiple blower motor speeds. OPERATION The Blower Motor Resistor limits speed of the blower motor so that it operates at four different speeds. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning > Page 5574 Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 5575 Blower Motor Switch: Description and Operation PURPOSE The Blower Switch allows the driver to select LO, MED LO, MED HI or HI blower motor speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams > Page 5576 Blower Motor Switch: Testing and Inspection Component Testing Procedure Schematic Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Solenoid <--> [Compressor Clutch] > Component Information > Specifications A/C Compressor Clutch Solenoid: Specifications Compressor Clutch Air Gap ................................................................................................................. ........................................................... 0.018-0.033 in Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > A/C Compressor Clutch Solenoid <--> [Compressor Clutch] > Component Information > Specifications > Page 5581 A/C Compressor Clutch Solenoid: Description and Operation OPERATION The Powertrain Control Module (PCM) monitors the A/C Clutch (ACC) apply signal. The PCM uses this signal to adjust the Idle Air Control-Bypass Air (IAC-BPA) valve to maintain the proper idle speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation Compressor Clutch Relay: Description and Operation PURPOSE When the vehicle operator goes to Wide Open Throttle (WOT), the Wide Open Throttle A/C (WOT A/C) relay opens, suspending A/C operation until normal vehicle operation resumes. This is done to allow maximum power to the drive wheels under heavy acceleration or load. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Condenser HVAC: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 5589 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5590 Condenser HVAC: Service and Repair Removal 1. Remove the radiator grille by removing the five plastic retainers located across the top of the grille. 2. Remove the two screws which attach the grille to the headlamp housing. 3. Then, use a flat-bladed tool to depress the spring tabs which are accessible through the lower outboard grille openings. Detach the grille from the headlamp housings. 4. Remove the grille from the vehicle. Radiator Vertical Extensions Installation 5. Install the two vertical radiator extensions as shown in the following illustration. They attach to the forward flanges on the right and left sides of the horse collar. The extensions are identical. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 5591 Condenser Core-to-Radiator Support Seals Condenser Core-to-Radiator Vertical Seals 6. Install a condenser upper seal on the rear surface of the radiator support which is adjacent to the upper right and left corners of the A/C condenser core. (The illustration which follows pinpoints the locations. Make sure the surface is clean prior to installation.) NOTE: Be sure to align the edge of the seal tightly against the adjacent sheet metal surface. 7. For accessibility, continue tilting the radiator and remove the right vertical condenser seal, and replace it. Seal installation is shown in the illustration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications A/C Coupler O-ring: Technical Service Bulletins A/C - New O Ring Applications Article No. 96-20-8 09/23/96 ^ AIR CONDITIONING - NEW 0-RING APPLICATIONS - THICKER 0-RINGS FOR SPRING LOCK FITTINGS - SERVICE TIP ^ AIR CONDITIONING - SPRING LOCK COUPLING CLEANING PROCEDURE - SERVICE TIP FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1991-94 CAPRI 1992 MARK VII 1992-94 TOPAZ 1992-97 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-96 BRONCO 1992-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, F-47, RANGER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 MOUNTAINEER ISSUE: A new air conditioning spring lock coupling cleaning procedure has been developed. This procedure is required for a thicker O-ring that has been released for servicing spring lock couplings. These O-rings have a larger cross-sectional diameter for improved sealing. The thicker O-ring is green in color and identifiable only by the part number. These are service only O-rings and will not be used in production. ACTION: Clean the Spring Lock Coupling(s) (SLC), if their service is required, and install the new thicker O-rings by referring to the following Service Procedure for details. SERVICE PROCEDURE 1. Recover refrigerant from the A/C system. 2. Disconnect SLC(s). 3. Remove old O-rings using a plastic O-ring tool and discard. Plastic O-ring Service Tools are available from Rotunda in the R-134a/R-12 Port kit (164R2602) or the 0-Ring Pick/Valve Core Removal Tool kit (164R2604). These items can be ordered by calling 1-800-768-8632 (Mon-Fri, 8AM-5PM EST). When prompted, press choice 2 for dealership supply orders. 4. Check the female SLC O-ring sealing surface for scratches, corrosion, or debris from deteriorated O-rings. Clean any surface residue from the inside of the couplings by using the following procedure (Steps 4a-4j): a. Obtain the following shop equipment and cleaning supplies locally: ^ 3-1/2" length of steel brazing rod ^ YN-9 (mineral) oil for R-12 systems or YN-12-B (PAG) oil for R-134a systems ^ Variable speed electric drill ^ Safety goggles or glasses Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5597 ^ Lint free cloth ^ 12" length of natural fiber string (twine or kite string) ^ Abrasive material - maroon colored 3M "Scotch Brite" pad cut in strips as follows: SLC Abrasive Strip Size Dimension 3/8" 1" X 2" 1/2" 1" X 2" 5/8" 1" X 3" 3/4" 1" x 4" b. Fabricate a cleaning tool (Figure 1). c. Determine coupling size and select the appropriate length of abrasive strip from the Step 4a table. d. Insert abrasive strip into the cleaning tool (Figure 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5598 e. Insert completed assembly into drill and tighten chuck securely. f. Coat the abrasive strip in appropriate refrigerant oil. g. Roll abrasive strip around cleaning tool (Figure 3). NOTE: DO NOT ALLOW THE DRILL SPEED TO EXCEED 1500 RPM AS TOOL SEPARATION MAY OCCUR. h. Using a variable speed drill set at a low speed, slowly insert cleaning assembly into the female coupling. Clean using a moderate speed for approximately 1 minute or until surface is clean. Maintain low speed drill rotation while removing the cleaning assembly to prevent axial scratches, which may cause future leaks. NOTE: IT IS IMPORTANT TO USE A LINT FREE CLOTH TO PREVENT MATERIAL FIBERS FROM REMAINING ON THE 0-RING SEALING SURFACE AND CAUSING FUTURE LEAKS. i. Remove all cleaning residue from the coupling using a lint free cloth. j. Inspect O-ring sealing surface for grooves. If grooves or scratches cannot be removed, replace the component. 5. Inspect the male SLC O-ring grooves for scratches, corrosion, or debris from O-ring deterioration. Remove any surface residue from the O-ring grooves by cleaning using the following procedure (Steps 5a-5b): Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5599 a. Loop the 12" length of natural fiber string around SLC and clean O-ring sealing surface (Figure 4). b. Remove all cleaning residue using a lint free cloth. NOTE: ONLY USE NEW GREEN 0-RINGS. THE USE OF ANY 0-RING SEALS OTHER THAN SPECIFIED MAY ALLOW CONNECTION TO LEAK INTERMITTENTLY DURING VEHICLE OPERATION. 6. Reassemble the SLC by referring to the following procedure (Steps 6a-6e): a. Lubricate the new O-ring seal using appropriate refrigerant oil. b. Install new O-rings. c. Lubricate the inside of the female coupling with the appropriate refrigerant oil. d. Install plastic indicator ring into cage opening if indicator ring is to be used. NOTE: IF THE PLASTIC INDICATOR RING IS USED, IT WILL SNAP OUT OF THE CAGE OPENING WHEN THE COUPLING IS CONNECTED TO INDICATE ENGAGEMENT. IF THE INDICATOR RING IS NOT USED, CHECK THE COUPLING ENGAGEMENT BY VERIFYING THAT THE GARTER SPRING IS OVER THE FLARED END OF THE FEMALE COUPLING. e. Fit female coupling to male coupling and push with a twisting motion until the garter spring snaps over the flared end of the female fitting. 7. Repeat procedure as necessary for any remaining couplings. Verify seal integrity by leak testing the coupling. If coupling continues to leak, replace the component. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5600 OASIS CODES: 208000, 208200, 2O8999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5601 A/C Coupler O-ring: Technical Service Bulletins A/C O Ring - Availability and Applications Article No. 96-20-7 09/23/96 AIR CONDITIONING - NEW 0-RING AVAILABILITY AND APPLICATIONS - SERVICE TIP FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992 and after ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1992-94 TOPAZ 1992 and after CONTINENTAL, COUGAR, SABLE, TRACER 1993-94 CAPRI 1993 and after MARK VIII 1995 and after MYSTIQUE LIGHT TRUCK: 1992 and after AEROSTAR, BRONCO, ECONOLINE, EXPLORER F-150-350 SERIES, F-47, RANGER 1993 and after VILLAGER 1995 and after WINDSTAR 1997 and after MOUNTAINEER MEDIUM/HEAVY TRUCK: 1992 and after F & B SERIES ISSUE: This bulletin provides climate control system O-ring part number information. ACTION: When servicing A/C systems, refer to the application charts for correct O-ring part numbers. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5602 The contents of O-ring Service kit F3VY-19D690-A* are as follows: ^ Two (2) 391304-S100** ^ Two (2) 391305-S100 ^ Two (2) 391396-S100** ^ Four (4) 391397-S100** * This O-ring kit will be obsolete and new O-rings will need to be ordered separately. ** These Part Numbers have been replaced by new thicker O-rings. They can be used until stock is depleted. The following are replacement numbers: ^ 391302-S100 replaced by W701993-S ^ 391303-S100 replaced by W701992-S ^ 391304-S100 replaced by W701994-S ^ 391396-S100 replaced by W701993-S ^ 391397-S100 replaced by W701992-S Parts Block OTHER APPLICABLE ARTICLES: 95-2-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5603 A/C Coupler O-ring: Technical Service Bulletins Air Conditioning - O Ring Removal Service Tip Article No. 95-2-2 01/30/95 AIR CONDITIONING - O-RING REMOVAL FROM SPRING LOCK COUPLER - SERVICE TIP FORD: 1981-95 MUSTANG 1982-83 FAIRMONT 1982-88 EXP 1982-95 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-95 TAURUS 1989-95 PROBE 1995 CONTOUR LINCOLN-MERCURY: 1982-83 LN7, ZEPHYR 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1991-95 TRACER 1993-94 CAPRI 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1982-95 BRONCO, F SUPER DUTY, F-150-350 SERIES, RANGER 1983-90 BRONCO II 1986-95 AEROSTAR 1988-95 ECONOLINE 1991-95 EXPLORER 1995 WINDSTAR This TSB is being republished in its entirety to include the latest level tools and procedures available. ISSUE: Some technicians may use small screwdrivers to remove 0-rings from spring lock coupling fittings. This practice can and has resulted in scratches across the 0-ring grooves in the fittings. Loss of refrigerant charge in the system may result. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New O Ring Applications > Page 5604 ACTION: It is recommended that a plastic toothpick, or equivalent tool, be used to remove 0-rings. Refer to Figure 1. Do not use the metal O-Ring Tool (T71P-19703-C). Only plastic O-Ring Tool (F5VH-17B017-AA) is approved for O-ring removal. OTHER APPLICABLE ARTICLES: 91-22-5, 93-6-5 SUPERSEDES: 93-15-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair Evaporator Case Assembly Removal NOTE: Evaporator case removal should only be required in unusual circumstances because all major components of the case assembly are serviceable without removing the case. 1. Disconnect the ground cable. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the PCM relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Discharge the refrigerant system. Observe all safety precautions. Please refer to Heating and Air Conditioning/Srevice and Repair/ See: Service and Repair 3. Disconnect the electrical hardshell connectors from the blower motor, the blower motor resistor and the pressure switch. 4. Disconnect the vacuum line from the check valve. 5. Disconnect the vacuum line from the vacuum source on the engine intake manifold; then, remove the line from the routing channel. 6. Disconnect the liquid line from the evaporator core inlet tube and cap the openings to prevent the entry of dirt and moisture. 7. Disconnect the suction line from the accumulator I drier with a Spring Lock Coupling Tool and cap the openings to prevent the entry of dirt and moisture, please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ NOTE: Please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ 8. Disconnect the heater hoses from the heater core tubes and plug the hoses with suitable 15.975mm (518 in.) plugs. Observe all safety precautions. 9. Remove the solenoid box cover, if so equipped, by removing the three bolts fastened through the fender liner. Remove the air cleaner and vacuum reservoir, if so equipped. 10. Remove three nuts from the engine compartment side of the evaporator assembly and one nut from the passenger compartment side of the assembly. 11. Remove the evaporator case assembly from the vehicle. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 5608 1. Before the evaporator case can be installed, it will be necessary to remove all insulation and install new. Apply RTV to any exposed staple holes. Three illustrations follow. The first shows the configuration of the insulators. The second shows how and where they are to be attached to the case. This second illustration also highlights the areas in which staples are not to be driven. CAUTION: A misplaced staple could damage the evaporator core or leave a perforation in the case with a resulting air or water leak in the system. 2. Using 3/16-inch staples, staple the three foil covered insulators to the case. Approximately 45 staples are needed to adequately secure the insulation to the case. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 5609 3. The third illustration shows the fully insulated case installed in the vehicle. 4. Add 4 ounces of refrigerant oil to the accumulator. Install the accumulator in the mounting bracket and attach the bracket to the evaporator case flanges. Attach the bracket around the evaporator core inlet tube. 5. Install the wrap-around insulators on the accumulator; then install the two bundling straps to secure the insulators to the accumulator. 6. Position the evaporator case assembly over the mounting studs in the dash panel. 7. In sequence, install a retaining nut on the stud located near the upper middle portion of the case; then install a nut on the stud located near the upper inboard end of the case. Next, install a nut on each of the two lower studs Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 951514 > Jul > 95 > A/C System - Lack of Cooling Evaporator Core: Customer Interest A/C System - Lack of Cooling Article No. 95-15-14 07/31/95 ^ AIR CONDITIONING - LACK OF COOLING - ORIFICE TUBE BLOCKING EVAPORATOR CORE - VEHICLES BUILT FROM 10/1/94 THROUGH 12/31/94 ^ AIR CONDITIONING - ORIFICE TUBE MISSING/OUT OF POSITION - VEHICLES BUILT 10/1/94 THROUGH 12/31/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A lack of A/C cooling may be observed on some vehicles. This may be due to an incorrect crimp on the evaporator inlet tube which retains the orifice tube in the proper position. This may allow the orifice tube to slip and lodge in the evaporator core. This condition may cause a restriction or appear that the orifice tube is missing, resulting in lack of cooling. ACTION: Replace the evaporator core and orifice tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the concern using the procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. 2. If the pressure cycling time test indicates a missing orifice tube or an evaporator restriction, recover the refrigerant using an approved refrigerant recovery system. 3. Disconnect the evaporator inlet tube and look for the orifice lodged inside the evaporator core. 4. If the orifice tube is lodged inside the evaporator core, replace the evaporator core and orifice tube. If the orifice tube is not lodged in the evaporator core, refer to Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual for diagnostic procedures. 5. Evacuate and recharge the A/C system according to procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. PART NUMBER PART NAME E3TZ-19860-C Evaporator core F3XY-19D990-A Orifice Tube OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951514A Replace A/C Evaporator 2.2 Hrs. Core And Orifice Tube DEALER CODING CONDITION BASIC PART NO. CODE 19860 55 OASIS CODES: 208200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Evaporator Core: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 5623 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 951514 > Jul > 95 > A/C System - Lack of Cooling Evaporator Core: All Technical Service Bulletins A/C System - Lack of Cooling Article No. 95-15-14 07/31/95 ^ AIR CONDITIONING - LACK OF COOLING - ORIFICE TUBE BLOCKING EVAPORATOR CORE - VEHICLES BUILT FROM 10/1/94 THROUGH 12/31/94 ^ AIR CONDITIONING - ORIFICE TUBE MISSING/OUT OF POSITION - VEHICLES BUILT 10/1/94 THROUGH 12/31/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A lack of A/C cooling may be observed on some vehicles. This may be due to an incorrect crimp on the evaporator inlet tube which retains the orifice tube in the proper position. This may allow the orifice tube to slip and lodge in the evaporator core. This condition may cause a restriction or appear that the orifice tube is missing, resulting in lack of cooling. ACTION: Replace the evaporator core and orifice tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the concern using the procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. 2. If the pressure cycling time test indicates a missing orifice tube or an evaporator restriction, recover the refrigerant using an approved refrigerant recovery system. 3. Disconnect the evaporator inlet tube and look for the orifice lodged inside the evaporator core. 4. If the orifice tube is lodged inside the evaporator core, replace the evaporator core and orifice tube. If the orifice tube is not lodged in the evaporator core, refer to Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual for diagnostic procedures. 5. Evacuate and recharge the A/C system according to procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. PART NUMBER PART NAME E3TZ-19860-C Evaporator core F3XY-19D990-A Orifice Tube OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951514A Replace A/C Evaporator 2.2 Hrs. Core And Orifice Tube DEALER CODING CONDITION BASIC PART NO. CODE 19860 55 OASIS CODES: 208200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement Evaporator Core: All Technical Service Bulletins A/C Evaporator Core - On Vehicle Leak Test Requirement Article No. 95-13-1 07/03/95 ^ AIR CONDITIONING - EVAPORATOR CORE - "ON-VEHICLE" LEAK TEST REQUIRED FOR WARRANTY CLAIM ^ AIR CONDITIONING - "ON-VEHICLE" EVAPORATOR CORE LEAK TEST REQUIRED FOR WARRANTY CLAIM FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1992 MARK VII 1992-94 CAPRI, TOPAZ 1992-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1992-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, F-47, RANGER 1993-95 VILLAGER 1995 WINDSTAR This TSB article is being republished in its entirety to correct the referenced Step for the cleaning procedure. ISSUE: An "on-vehicle" air conditioning evaporator core leak test is required before replacing any A/C evaporator core within the warranty period. ACTION: Perform the "on-vehicle" air conditioning evaporator core leak test before replacing the evaporator core. Refer to the following Evaporator Core Leak Test Procedure. EVAPORATOR CORE LEAK TEST PROCEDURE NOTE: ALL FITTINGS REQUIRED TO PERFORM THE LEAK TEST ARE INCLUDED IN TEST ADAPTER KIT D93L-1 9703-B OR EQUIVALENT. CAUTION: DISCONNECT THE LIQUID LINE AND SUCTION ACCUMULATOR FROM THE EVAPORATOR CORE TUBES. DO NOT LEAK TEST AN EVAPORATOR CORE WITH THE SUCTION ACCUMULATOR ATTACHED TO THE CORE TUBES. REFRIGERANT OUTGASSING FROM OIL AND DESICCANT IN THE ACCUMULATOR WILL INDICATE A FALSE LEAK CONDITION. 1. Verify that the manifold gauge set is capable of holding vacuum. a. Connect the RED and BLUE hoses together using a 1/4" (6.35 mm) flare coupling. b. Connect the gauge set YELLOW hose to a known good vacuum pump. c. Turn the vacuum pump ON and open both gauge set valves. d. Operate the vacuum pump for 1 minute and close both gauge set valves. The low side gauge should indicate approximately 30" of vacuum. e. Allow the gauge set, with vacuum applied, to sit for at least 30 minutes. f. If the gauge reading drops during that time, the gauge set hose connections, gauges, or valves are leaking and should be repaired before proceeding with the leak test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement > Page 5632 2. Clean the evaporator core tube fittings. a. For threaded connections, wipe any dirt or debris from the sealing surfaces with a clean lint-free rag. b. If the evaporator core tube fittings are the female Spring Lock design, check the inside of each fitting for scratches, corrosion, or debris from deteriorated 0-rings. c. If scratches, corrosion, or debris are found, the leak test results may not be accurate unless the fitting is properly cleaned. Refer to Step 3 for cleaning procedure. 3. Clean the Spring Lock fittings as follows: a. Remove any surface residue from the inside of the female Spring Lock Coupling by polishing with 400 grit emery cloth or equivalent. b. Polish the female surface by using a twisting motion so that any scratches made will not cross the 0-ring sealing surface. See Figure 1. c. Perform additional polishing of surface using 600 grit emery cloth or equivalent. d. Remove all residue from the polishing operations by wiping the fittings with a lint-free rag. e. Connect the appropriate test fittings from Test Adapter Kit D93L-19703-B, or equivalent, to the evaporator tube connections. 5. Connect the RED and BLUE hoses from the manifold gauge set to the test fittings on the evaporator core. Connect the YELLOW hose to a known quality vacuum pump. NOTE: THE AUTOMATIC SHUTOFF VALVES ON SOME GAUGE SET HOSES DO NOT OPEN WHEN CONNECTED TO THE TEST FITTINGS. IF AVAILABLE, USE HOSES WITHOUT SHUTOFF VALVES. IF HOSES WITH SHUTOFF VALVES ARE USED, CHECK TO BE SURE THE VALVE OPENS WHEN ATTACHED TO THE TEST FITTINGS OR INSTALL AN ADAPTER WHICH WILL ACTIVATE THE VALVE. THE TEST IS NOT VALID IF THE SHUTOFF VALVE DOES NOT OPEN, ONLY THE HOSE WILL BE TESTED. 6. Open both gauge set valves and start the vacuum pump. a. Turn the A/C system blower on low to allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 30" Hg. The 45 minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core. b. If the refrigerant is not completely removed from the oil, outgassing will occur and degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 30" Hg when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the evaporator core. 8. The following information is helpful in determining if a leak is present. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement > Page 5633 ^ If the low pressure gauge reading rises 10 or more inches of vacuum from the 30" position in 10 minutes, a leak is indicated. ^ If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with the gauge valves open for an additional 30 minutes with the system blower on low to remove any remaining refrigerant from the oil in the evaporator core. Then, recheck for loss of vacuum as outlined. ^ If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. NOTE: ALWAYS REMEMBER THAT A LEAKING FITTING, GAUGE SET OR HOSE CONNECTION WILL APPEAR AS A LEAKING EVAPORATOR CORE. 9. If the evaporator core does leak, as verified by the above procedure, install a new evaporator core. Follow the appropriate Service Manual procedure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-10-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 290000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Evaporator Core: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 5639 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement Evaporator Core: All Technical Service Bulletins A/C Evaporator Core - On Vehicle Leak Test Requirement Article No. 95-13-1 07/03/95 ^ AIR CONDITIONING - EVAPORATOR CORE - "ON-VEHICLE" LEAK TEST REQUIRED FOR WARRANTY CLAIM ^ AIR CONDITIONING - "ON-VEHICLE" EVAPORATOR CORE LEAK TEST REQUIRED FOR WARRANTY CLAIM FORD: 1992-93 FESTIVA 1992-94 TEMPO 1992-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1992 MARK VII 1992-94 CAPRI, TOPAZ 1992-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1992-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, F-47, RANGER 1993-95 VILLAGER 1995 WINDSTAR This TSB article is being republished in its entirety to correct the referenced Step for the cleaning procedure. ISSUE: An "on-vehicle" air conditioning evaporator core leak test is required before replacing any A/C evaporator core within the warranty period. ACTION: Perform the "on-vehicle" air conditioning evaporator core leak test before replacing the evaporator core. Refer to the following Evaporator Core Leak Test Procedure. EVAPORATOR CORE LEAK TEST PROCEDURE NOTE: ALL FITTINGS REQUIRED TO PERFORM THE LEAK TEST ARE INCLUDED IN TEST ADAPTER KIT D93L-1 9703-B OR EQUIVALENT. CAUTION: DISCONNECT THE LIQUID LINE AND SUCTION ACCUMULATOR FROM THE EVAPORATOR CORE TUBES. DO NOT LEAK TEST AN EVAPORATOR CORE WITH THE SUCTION ACCUMULATOR ATTACHED TO THE CORE TUBES. REFRIGERANT OUTGASSING FROM OIL AND DESICCANT IN THE ACCUMULATOR WILL INDICATE A FALSE LEAK CONDITION. 1. Verify that the manifold gauge set is capable of holding vacuum. a. Connect the RED and BLUE hoses together using a 1/4" (6.35 mm) flare coupling. b. Connect the gauge set YELLOW hose to a known good vacuum pump. c. Turn the vacuum pump ON and open both gauge set valves. d. Operate the vacuum pump for 1 minute and close both gauge set valves. The low side gauge should indicate approximately 30" of vacuum. e. Allow the gauge set, with vacuum applied, to sit for at least 30 minutes. f. If the gauge reading drops during that time, the gauge set hose connections, gauges, or valves are leaking and should be repaired before proceeding with the leak test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement > Page 5644 2. Clean the evaporator core tube fittings. a. For threaded connections, wipe any dirt or debris from the sealing surfaces with a clean lint-free rag. b. If the evaporator core tube fittings are the female Spring Lock design, check the inside of each fitting for scratches, corrosion, or debris from deteriorated 0-rings. c. If scratches, corrosion, or debris are found, the leak test results may not be accurate unless the fitting is properly cleaned. Refer to Step 3 for cleaning procedure. 3. Clean the Spring Lock fittings as follows: a. Remove any surface residue from the inside of the female Spring Lock Coupling by polishing with 400 grit emery cloth or equivalent. b. Polish the female surface by using a twisting motion so that any scratches made will not cross the 0-ring sealing surface. See Figure 1. c. Perform additional polishing of surface using 600 grit emery cloth or equivalent. d. Remove all residue from the polishing operations by wiping the fittings with a lint-free rag. e. Connect the appropriate test fittings from Test Adapter Kit D93L-19703-B, or equivalent, to the evaporator tube connections. 5. Connect the RED and BLUE hoses from the manifold gauge set to the test fittings on the evaporator core. Connect the YELLOW hose to a known quality vacuum pump. NOTE: THE AUTOMATIC SHUTOFF VALVES ON SOME GAUGE SET HOSES DO NOT OPEN WHEN CONNECTED TO THE TEST FITTINGS. IF AVAILABLE, USE HOSES WITHOUT SHUTOFF VALVES. IF HOSES WITH SHUTOFF VALVES ARE USED, CHECK TO BE SURE THE VALVE OPENS WHEN ATTACHED TO THE TEST FITTINGS OR INSTALL AN ADAPTER WHICH WILL ACTIVATE THE VALVE. THE TEST IS NOT VALID IF THE SHUTOFF VALVE DOES NOT OPEN, ONLY THE HOSE WILL BE TESTED. 6. Open both gauge set valves and start the vacuum pump. a. Turn the A/C system blower on low to allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 30" Hg. The 45 minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core. b. If the refrigerant is not completely removed from the oil, outgassing will occur and degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 30" Hg when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the evaporator core. 8. The following information is helpful in determining if a leak is present. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95131 > Jul > 95 > A/C Evaporator Core - On Vehicle Leak Test Requirement > Page 5645 ^ If the low pressure gauge reading rises 10 or more inches of vacuum from the 30" position in 10 minutes, a leak is indicated. ^ If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. ^ If a small amount of vacuum is lost, operate the vacuum pump with the gauge valves open for an additional 30 minutes with the system blower on low to remove any remaining refrigerant from the oil in the evaporator core. Then, recheck for loss of vacuum as outlined. ^ If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss. NOTE: ALWAYS REMEMBER THAT A LEAKING FITTING, GAUGE SET OR HOSE CONNECTION WILL APPEAR AS A LEAKING EVAPORATOR CORE. 9. If the evaporator core does leak, as verified by the above procedure, install a new evaporator core. Follow the appropriate Service Manual procedure. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-10-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 290000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5646 Evaporator Core: Service and Repair Evaporator Core Assembly NOTE: If the evaporator core is replaced, the suction accumulator/drier must also be replaced. Removal 1. Disconnect the cable from the battery negative (ground) terminal. 2. Discharge the refrigerant from the A/C system following the recommended service procedure in Air Conditioning General Service. Observe all safety precautions. Please refer to Heating ad Air Conditioning/Service and Repair/ See: Service and Repair 3. Disconnect the electrical connector from the pressure switch located on top of the accumulator/drier. 4. Remove the pressure switch from the accumulator/drier. 5. Disconnect the suction hose from the accumulator/drier, using the Spring Lock Coupling Tool and cap openings to prevent dirt and/or moisture from entering, please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ NOTE: Please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ 6. Disconnect the liquid line from the evaporator core inlet tube using a backup wrench to loosen the fitting. Cap the openings to prevent dirt and/or moisture from entering. 7. Remove the screws holding the evaporator case service cover and vacuum reservoir to the evaporator case assembly. 8. Store the vacuum reservoir in a secure position to avoid vacuum line damage. 9. Remove two dash panel mounting nuts. 10. Remove the evaporator case service cover from the evaporator case assembly. 11. Remove the evaporator core and suction accumulator/drier assembly from the vehicle. Installation 1. Position the evaporator core and accumulator/drier assembly into the install evaporator case out-board half. 2. Position the evaporator case service cover into place on the evaporator case assembly. 3. Install the two dash panel mounting nuts. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 5647 4. Install the screws holding the evaporator service case half to the evaporator case assembly. 5. Place the vacuum reservoir in its installed position. Attach the reservoir to the case with two screws. 6. Connect the liquid line to the evaporator inlet tube using a backup wrench to tighten the fitting to specification. (Install a new lubricated 0-ring.) 7. Connect the suction hose to the suction accumulator / drier after checking for a missing or damaged spring lock coupling garter spring and/or repairing or replacing the spring. Install two new specified (special material) 0-rings, lubricated with clean refrigerant oil,onto the spring lock coupling male fitting. NOTE: Refer to Spring Lock Coupling in Heating and Air Conditioning/ 8. Install (screw) the pressure switch to the accumulator/drier and tighten finger-tight. CAUTION: DO NOT use a wrench to tighten the pressure switch. 9. Connect the electrical connector to the pressure switch. 10. Charge the A/C system following the recommended service procedures. Observe all safety precautions. Please refer to Heating ad Air Conditioning/Service and Repair/ See: Service and Repair 11. Connect the cable to the battery negative (ground) terminal. 12. Check the A/C system for refrigerant leaks and proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > Customer Interest for Expansion Block/Orifice Tube: > 951514 > Jul > 95 > A/C System - Lack of Cooling Expansion Block/Orifice Tube: Customer Interest A/C System - Lack of Cooling Article No. 95-15-14 07/31/95 ^ AIR CONDITIONING - LACK OF COOLING - ORIFICE TUBE BLOCKING EVAPORATOR CORE - VEHICLES BUILT FROM 10/1/94 THROUGH 12/31/94 ^ AIR CONDITIONING - ORIFICE TUBE MISSING/OUT OF POSITION - VEHICLES BUILT 10/1/94 THROUGH 12/31/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A lack of A/C cooling may be observed on some vehicles. This may be due to an incorrect crimp on the evaporator inlet tube which retains the orifice tube in the proper position. This may allow the orifice tube to slip and lodge in the evaporator core. This condition may cause a restriction or appear that the orifice tube is missing, resulting in lack of cooling. ACTION: Replace the evaporator core and orifice tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the concern using the procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. 2. If the pressure cycling time test indicates a missing orifice tube or an evaporator restriction, recover the refrigerant using an approved refrigerant recovery system. 3. Disconnect the evaporator inlet tube and look for the orifice lodged inside the evaporator core. 4. If the orifice tube is lodged inside the evaporator core, replace the evaporator core and orifice tube. If the orifice tube is not lodged in the evaporator core, refer to Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual for diagnostic procedures. 5. Evacuate and recharge the A/C system according to procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. PART NUMBER PART NAME E3TZ-19860-C Evaporator core F3XY-19D990-A Orifice Tube OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951514A Replace A/C Evaporator 2.2 Hrs. Core And Orifice Tube DEALER CODING CONDITION BASIC PART NO. CODE 19860 55 OASIS CODES: 208200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Expansion Block/Orifice Tube: > 951514 > Jul > 95 > A/C System - Lack of Cooling Expansion Block/Orifice Tube: All Technical Service Bulletins A/C System - Lack of Cooling Article No. 95-15-14 07/31/95 ^ AIR CONDITIONING - LACK OF COOLING - ORIFICE TUBE BLOCKING EVAPORATOR CORE - VEHICLES BUILT FROM 10/1/94 THROUGH 12/31/94 ^ AIR CONDITIONING - ORIFICE TUBE MISSING/OUT OF POSITION - VEHICLES BUILT 10/1/94 THROUGH 12/31/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A lack of A/C cooling may be observed on some vehicles. This may be due to an incorrect crimp on the evaporator inlet tube which retains the orifice tube in the proper position. This may allow the orifice tube to slip and lodge in the evaporator core. This condition may cause a restriction or appear that the orifice tube is missing, resulting in lack of cooling. ACTION: Replace the evaporator core and orifice tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the concern using the procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. 2. If the pressure cycling time test indicates a missing orifice tube or an evaporator restriction, recover the refrigerant using an approved refrigerant recovery system. 3. Disconnect the evaporator inlet tube and look for the orifice lodged inside the evaporator core. 4. If the orifice tube is lodged inside the evaporator core, replace the evaporator core and orifice tube. If the orifice tube is not lodged in the evaporator core, refer to Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual for diagnostic procedures. 5. Evacuate and recharge the A/C system according to procedures outlined in Section 12 of the 1994 Aerostar, Ranger, Explorer Service Manual. PART NUMBER PART NAME E3TZ-19860-C Evaporator core F3XY-19D990-A Orifice Tube OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951514A Replace A/C Evaporator 2.2 Hrs. Core And Orifice Tube DEALER CODING CONDITION BASIC PART NO. CODE 19860 55 OASIS CODES: 208200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > Page 5661 Expansion Block/Orifice Tube: Locations A/C Orifice Tube The A/C evaporator core orifice is located in the A/C evaporator core inlet tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > Page 5662 Expansion Block/Orifice Tube: Service and Repair A/C Orifice Tube Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > Page 5663 Fig. 2 Spring lock coupling disconnect & connect Removal 1. Discharge refrigerant from system. 2. Disconnect and cap liquid line from evaporator core inlet tube. 3. Pour a small amount of refrigerant oil into inlet tube to lubricate orifice tube O-rings and inlet tube. 4. Using tool D80L-19990-A or equivalent, engage with the two tangs on the orifice tube. CAUTION: Do not twist or rotate the fixed orifice tube in the evaporator core inlet tube, as it may break off. 5. Hold T-handle of removal tool to prevent it from turning, and run nut down against evaporator core tube until orifice tube is pulled from inlet tube. 6. If the A/C Evaporator Core Orifice breaks in tube, it must be removed from the tube with Broken Orifice Tube Extractor D80L-19990-B. 7. To remove a broken Orifice Tube, insert the screw end of the Extractor Tool into the tube and thread the screw end of the tool into the brass tube in the center of the orifice body. Then pull the orifice from the tube. 8. If only the brass tube is removed in step 7, insert the screw end of the extractor tool into the orifice body. Then pull the body from the tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Technical Service Bulletins > Page 5664 Installation 1. Lubricate the O-rings on the A/C Evaporator cor orifice liberally with clean refrigerant oil. 2. Place the orifice in the remover/replacer tool and insert into the evaporator tube until the orifice is seated at the stop. 3. Remove the tool from the orifice. 4. After checking the condenser to evaporator tube coupling end for a missing or damaged spring, install two new O-rings lubricated with clean refrigerant oil onto the male fitting. Insert the male fitting into the inlet tube until the spring lock coupling is fully engaged. 5. Leak test, evacuate and charge system. 6. Check system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim Heater Core: Technical Service Bulletins Heater Core - On Car Pressure Test For Warranty Claim Article No. 97-19-11 09/15/97 COOLING SYSTEM - "ON-VEHICLE" HEATER CORE PRESSURE TEST REQUIRED FOR WARRANTY CLAIM FORD: 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-98 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: An "On-Vehicle" heater core pressure test is required before replacing any heater core within the warranty period. ACTION: Perform the "On-Vehicle" heater core pressure test by referring to the following heater core leak test procedure. HEATER CORE LEAK TEST PROCEDURE Use the heater core pressure test to determine if the heater core is leaking. Symptoms associated with a leaking heater core include: ^ Engine coolant leaking into the passenger compartment ^ Engine coolant blown onto the windshield during defrost operation ^ Engine coolant odor inside the passenger compartment 1. Partially drain cooling system. 2. Disconnect both heater core hoses. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - On Car Pressure Test For Warranty Claim > Page 5669 3. Attach two (2) pieces of heater hose to the heater core inlet and outlet tubes and clamp (Figure 1). 4. Install Plug (part of 014-R1072) into one (1) heater hose and clamp (Figure 1). 5. Fill heater core and hoses with water. 6. Install Adapter (part of 0144-R1072) into other heater hose and clamp (Figure 1). 7. Attach Radiator/Heater Core Pressure Tester (014-R1072) to Adapter (part of 014-R1072) (Figure 1). 8. Close the bleed valve and the tester and pump air into the heater core until 241 kPa (35 psi) is reached on the tester gauge. 9. Observe the gauge after 3 minutes. The pressure should not drop. If the pressure does drop, there is a leak. Check the hose connections and retest if you find a leak. 10. Replace heater core if pressure drops and hose connections do not leak. 11. Do not replace heater core if pressure does not drop. Pressure test engine cooling system for leaks elsewhere. 12. Reconnect heater core and refill cooling system after all necessary repairs. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 208999, 290000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 5670 Heater Core: Service and Repair Removal Heater Core 1. Allow the engine to cool. Following all safety precautions and using a thick cloth, turn the radiator cap slowly to the first stop. Step back while pressure is released. When the pressure is released, tighten the radiator cap on the radiator. 2. Disconnect heater hoses from heater core tubes and plug the hoses. 3. In passenger compartment, remove four screws attaching heater core access cover to plenum assembly. Remove access cover. 4. Pull heater core rearward and down, removing it from plenum assembly. Installation 1. Position the heater core and seal in the plenum assembly. 2. Install the heater core access cover to the plenum assembly and secure it with four screws. Ensure the cover is sealed correctly before tightening the screws. 3. Install the heater hoses to the heater core tubes at the dash panel in the engine compartment. Position the hose clamps and tighten to 1.8-2.5 Nm (16-22 ilbs). 4. Check the coolant level and coolant as needed. 5. Check the system for proper operation and coolant leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > Customer Interest for Heater Core Case: > 941017 > May > 94 > Blower Motor - Whistle Noise On High Speed Heater Core Case: Customer Interest Blower Motor - Whistle Noise On High Speed Article No. 94-10-17 05/18/94 ^ HEATER - WHISTLE NOISE IN HIGH BLOWER ON FULL HEAT - VEHICLES BUILT THROUGH 12/22/93 ^ NOISE - "WHISTLE" SOUND IN HIGH BLOWER ON FULL HEAT - VEHICLES BUILT THROUGH 12/22/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A "whistling" noise may come from the dash while the blower motor is on high speed and the temperature control is on FULL HEAT. It goes away as the knob is turned toward COOL. This "whistle" may be caused by a gap between the two plenum case halves where the blend door is positioned in FULL HEAT. ACTION: Seal any seam leaks in the plenum to eliminate the "whistling" noise. Refer to the following procedure for service details. 1. Verify that the "whistle" is caused by a seam leak in the plenum or a body seal issue. a. With the engine running, heater blower set at high speed, and the temperature lever in full heat position, confirm that the "whistle" exists. b. Roll down one of the windows at least 1" (25.4 mm). ^ If the "whistle" goes away, then the concern is a body seal leak and should be located using body leak detection methods. ^ If the "whistle" remains, a plenum seal leak exists. Refer to Step 2. 2. Remove the plenum. Refer to the appropriate Service Manual, Sections 12-02B and 12-03B, for the removal procedures. 3. Locate any seal leaks in the removed plenum and seal with rope sealer (D6AZ-19560-A) or equivalent. 4. Reinstall the plenum assembly and verify that the "whistle" does not exist. Refer to the appropriate Service Manual, Sections 12-02B and 12-03B, for the installation procedures. PART NUMBER PART NAME CLASS D6AZ-19560-A Rope Sealer (Or Equivalent) AG WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941017A Reseal Plenum Chamber 3.5 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 19850 68 OASIS CODES: 208000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core Case: > 941017 > May > 94 > Blower Motor - Whistle Noise On High Speed Heater Core Case: All Technical Service Bulletins Blower Motor - Whistle Noise On High Speed Article No. 94-10-17 05/18/94 ^ HEATER - WHISTLE NOISE IN HIGH BLOWER ON FULL HEAT - VEHICLES BUILT THROUGH 12/22/93 ^ NOISE - "WHISTLE" SOUND IN HIGH BLOWER ON FULL HEAT - VEHICLES BUILT THROUGH 12/22/93 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A "whistling" noise may come from the dash while the blower motor is on high speed and the temperature control is on FULL HEAT. It goes away as the knob is turned toward COOL. This "whistle" may be caused by a gap between the two plenum case halves where the blend door is positioned in FULL HEAT. ACTION: Seal any seam leaks in the plenum to eliminate the "whistling" noise. Refer to the following procedure for service details. 1. Verify that the "whistle" is caused by a seam leak in the plenum or a body seal issue. a. With the engine running, heater blower set at high speed, and the temperature lever in full heat position, confirm that the "whistle" exists. b. Roll down one of the windows at least 1" (25.4 mm). ^ If the "whistle" goes away, then the concern is a body seal leak and should be located using body leak detection methods. ^ If the "whistle" remains, a plenum seal leak exists. Refer to Step 2. 2. Remove the plenum. Refer to the appropriate Service Manual, Sections 12-02B and 12-03B, for the removal procedures. 3. Locate any seal leaks in the removed plenum and seal with rope sealer (D6AZ-19560-A) or equivalent. 4. Reinstall the plenum assembly and verify that the "whistle" does not exist. Refer to the appropriate Service Manual, Sections 12-02B and 12-03B, for the installation procedures. PART NUMBER PART NAME CLASS D6AZ-19560-A Rope Sealer (Or Equivalent) AG WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941017A Reseal Plenum Chamber 3.5 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 19850 68 OASIS CODES: 208000, 702000, 702100 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 951615 > Aug > 95 > Air Conditioning - Whistling Noise Housing Assembly HVAC: Customer Interest Air Conditioning - Whistling Noise Article No. 95-16-15 08/14/95 ^ AIR CONDITIONING - "WHISTLE" NOISE WITH A/C CONTROLS IN "OFF" OR "MAX A/C" POSITIONS - VEHICLES BUILT FROM 2/11/94 THROUGH 11/1/94 ^ NOISE - "WHISTLE" - WITH A/C CONTROLS IN "OFF" OR "MAX A/C" MODE - VEHICLES BUILT FROM 2/11/94 THROUGH 11/1/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A "whistle" noise may be heard on some vehicles while driving with the A/C controls set in the "OFF" or "MAX A/C" positions. This may be caused by outside air leaking past the "recirc" door seal. ACTION: Replace the "recirc" door with a new "recirc" door which has an improved seal. This new "recirc" door should reduce the possibility of air leaking past the seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the heater air plenum housing as outlined on Page 12-03B-39 of the 1994 Ranger/Explorer Service Manual. 2. Disconnect the "recirc" door vacuum motor linkage from the crank arm. 3. Remove crank arm and "recirc" door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Customer Interest for Housing Assembly HVAC: > 951615 > Aug > 95 > Air Conditioning - Whistling Noise > Page 5692 4. Insert the new "recirc" door (E9TZ-19C802-A) into plenum housing (Figures 1 and 2). 5. Hold the new "recirc" door in place and snap the new crank arm (E9TZ-19A580-A) in place through the plenum housing. 6. Reconnect the "recirc" door vacuum motor linkage to the crank arm. 7. Reinstall the heater air plenum housing following the procedure outlined on Page 12-03B-39 of the 1994 Ranger/Explorer Service Manual. PART NUMBER PART NAME E9TZ-19C802-A Recirc Door E9TZ-19A580-A Crank Arm OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951615A Replace Recirc Door 3.4 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 19C802 77 OASIS CODES: 208000, 208300, 208999, 701000, 702000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 951615 > Aug > 95 > Air Conditioning Whistling Noise Housing Assembly HVAC: All Technical Service Bulletins Air Conditioning - Whistling Noise Article No. 95-16-15 08/14/95 ^ AIR CONDITIONING - "WHISTLE" NOISE WITH A/C CONTROLS IN "OFF" OR "MAX A/C" POSITIONS - VEHICLES BUILT FROM 2/11/94 THROUGH 11/1/94 ^ NOISE - "WHISTLE" - WITH A/C CONTROLS IN "OFF" OR "MAX A/C" MODE - VEHICLES BUILT FROM 2/11/94 THROUGH 11/1/94 LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: A "whistle" noise may be heard on some vehicles while driving with the A/C controls set in the "OFF" or "MAX A/C" positions. This may be caused by outside air leaking past the "recirc" door seal. ACTION: Replace the "recirc" door with a new "recirc" door which has an improved seal. This new "recirc" door should reduce the possibility of air leaking past the seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the heater air plenum housing as outlined on Page 12-03B-39 of the 1994 Ranger/Explorer Service Manual. 2. Disconnect the "recirc" door vacuum motor linkage from the crank arm. 3. Remove crank arm and "recirc" door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 951615 > Aug > 95 > Air Conditioning Whistling Noise > Page 5698 4. Insert the new "recirc" door (E9TZ-19C802-A) into plenum housing (Figures 1 and 2). 5. Hold the new "recirc" door in place and snap the new crank arm (E9TZ-19A580-A) in place through the plenum housing. 6. Reconnect the "recirc" door vacuum motor linkage to the crank arm. 7. Reinstall the heater air plenum housing following the procedure outlined on Page 12-03B-39 of the 1994 Ranger/Explorer Service Manual. PART NUMBER PART NAME E9TZ-19C802-A Recirc Door E9TZ-19A580-A Crank Arm OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 951615A Replace Recirc Door 3.4 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 19C802 77 OASIS CODES: 208000, 208300, 208999, 701000, 702000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater Housing Assembly HVAC: Service and Repair Air Flow Control Box - Heater Heater Plenum Assembly Removal 1. Disconnect the battery ground cable(s). 2. Remove heater hoses from core tubes and plug hoses. Please refer to Heating and Air Conditioning/Heater Core/Service and Repair/ See: Heater Core/Service and Repair 3. Remove the heater blower assembly. Please refer to Heating and Air Conditioning/Blower Motor/Servie and Repair/See: Blower Motor/Service and Repair 4. Remove the remaining nuts which secure the plenum to the dash panel on the engine side of the panel. 5. In the passenger compartment, remove the instrument panel. Please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Pull plenum rearward from the dash panel and remove from the vehicle. Installation 1. Position the plenum to the dash panel, aligning the studs with the holes in the panel. 2. Install the nuts on the plenum studs at the dash panel in the engine compartment (one stud is located below heater core tubes and one is located at the bottom of the plenum). 3. Install heater blower assembly. Please refer to Heating and Air Conditioning/Blower Motor/Servie and Repair/See: Blower Motor/Service and Repair 4. Install the heater hoses on the heater core tubes. Please refer to Heating and Air Conditioning/Heater Core/Service and Repair/ See: Heater Core/Service and Repair 5. Install the instrument panel. Please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Connect the battery ground cable(s). Check the system for proper operation. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Air Flow Control Box - Heater > Page 5701 Housing Assembly HVAC: Service and Repair Air Flow Control Box - A/C Air Conditioning Plenum Assembly Removal 1. Disconnect the battery ground cable(s). 2. Remove heater hoses from core tubes and plug hoses. Please refer to Heating and Air Conditioning/Heater Core/Service and Repair/ See: Heater Core/Service and Repair 3. Remove the evaporator assembly. Please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 4. Remove the remaining nuts which secure the plenum to the dash panel on the engine side of the panel. 5. In the passenger compartment, remove the instrument panel. Please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Pull plenum rearward from the dash panel and remove from the vehicle. Installation 1. Position the plenum to the dash panel, aligning the studs with the holes in the panel. 2. Install the nuts on the plenum studs at the dash panel in the engine compartment (one stud is located below heater core tubes and one is located at the bottom of the plenum). 3. Install evaporator assembly. Please refer to Heating and Air Conditioning/Evaporator Case/Service and Repair/ See: Evaporator Case/Service and Repair 4. Install the heater hoses on the heater core tubes. Please refer to Heating and Air Conditioning/Heater Core/Service and Repair/ See: Heater Core/Service and Repair 5. Install the instrument panel. Please refer to Body and Frame/Interior Trim/Dash Board/Service and Repair/ See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 6. Connect the battery ground cable(s). Check the system for proper operation. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5706 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5707 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5708 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5709 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5710 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5711 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5712 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5713 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5714 Refrigerant: Technical Service Bulletins A/C - Release of R134a Fluorescent Dye Article No. 94-26-6 12/26/94 AIR CONDITIONING - RELEASE OF R-134A FLUORESCENT TRACER DYE - FOR 1992 TAURUS, R-134A VEHICLES ONLY - SERVICE TIP FORD: 1992-95 TAURUS 1994-95 ASPIRE, CROWN VICTORIA, ESCORT, MUSTANG, PROBE, THUNDERBIRD 1994 TEMPO 1995 CONTOUR LINCOLN-MERCURY: 1993-95 MARK VIII 1994-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994 CAPRI, TOPAZ 1995 MYSTIQUE LIGHT TRUCK: 1994-95 AEROSTAR, BRONCO, ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995 WINDSTAR ISSUE: Ford Motor Company has approved an R-134a Fluorescent Tracer Dye (Rotunda Part, 112-ROO40) for use in checking R-134a A/C systems for refrigerant leaks. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 5715 ACTION: When leak checking an R-134a system, install the 112-R0040 dye using a Rotunda Dye lnjector (164-R2610). Use the procedures in Figure 1 when leak checking. This method of leak detection is an approved alternate to electronic leak detection and vacuum decay leak detection. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacity ............................................................................................................... ...................................................................... 26 oz Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 5718 Refrigerant: Fluid Type Specifications R-134a Hydrofluorocarbon(HFC) ................................................................................................................................. WSH-M17B19A Motorcraft YN-11 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5723 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5724 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 5725 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: Customer Interest A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > Customer Interest: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 5734 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 5740 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure Refrigerant Oil: All Technical Service Bulletins A/C - Insufficient Cooling/ Compressor Failure Article No. 97-10-5 05/12/97 ^ AIR CONDITIONING - COMPRESSOR FAILURE - INSUFFICIENT AMOUNT OF REFRIGERANT OIL ^ AIR CONDITIONING - LACK OF COOLING - INSUFFICIENT AMOUNT OF REFRIGERANT OIL MAY CAUSE COMPRESSOR FAILURE FORD: 1994-97 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1994-97 COUGAR LIGHT TRUCK: 1993-96 BRONCO 1993-97 F-150-350 SERIES, F-47 1994-95 ECONOLINE 1994-96 VILLAGER 1994-97 AEROSTAR, EXPLORER, RANGER 1995-96 WINDSTAR 1997 MOUNTAINEER This TSB article is being republished in its entirety to include 1997 F-Series. ISSUE: Some vehicles may exhibit air conditioner compressor failure due to an insufficient amount of refrigerant oil in the system. ACTION: Whenever service is required on the A/C system, add the appropriate refrigerant oil to the system. Refer to the following Service Procedure for details. NOTE: USE MOTORCRAFT YN-9 REFRIGERANT COMPRESSOR OIL FOR 1993 MODELS EQUIPPED WITH AN R-12 SYSTEM. FOR 1994 AND LATER MODELS USING AN R-134a SYSTEM, USE MOTORCRAFT YN-12-B POLYALKYLENE GLYCOL (PAG) REFRIGERANT COMPRESSOR OIL. SERVICE PROCEDURE 1. Remove all refrigerant from the A/C system using the appropriate R-12 or R-134a refrigerant recovery equipment following the manufacturer's operating instructions. 2. Service the A/C system as required. 3. Check for Modification Label indicating additional refrigerant oil is already in place. 4. If no label was found, add additional clean refrigerant oil (over and above the amount of oil required for the system being serviced). The oil may be poured directly into the accumulator assembly or it may be injected by the refrigerant charging station, if so equipped. 5. Recharge the A/C system using the appropriate refrigerant. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 97-10-5 > May > 97 > A/C - Insufficient Cooling/ Compressor Failure > Page 5745 Obtain an Authorized Modification Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME YN-9 Refrigerant Oil (R-12 Systems) YN-12-B Refrigerant Oil (R-134a Systems) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-22-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Oil: > 94156 > Jul > 94 > A/C Compressor - Service Tips Refrigerant Oil: All Technical Service Bulletins A/C Compressor - Service Tips Article No. 94-15-6 07/27/94 AIR CONDITIONING - FS-10 AND FX-15 COMPRESSORS - SERVICE TIPS FORD: 1988-94 CROWN VICTORIA, ESCORT, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 MARK VII 1988-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-94 TRACER 1993-94 MARK VIII LIGHT TRUCK: 1988-90 BRONCO II 1988-94 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: FS-10 service compressors built between 1/1/93 and 9/30/93 were built with 7 oz. of oil. These compressors have a white label and are labeled to be compatible with either R-12 or R-134a. These compressors contain either PAG oil or Mineral oil and should be used only in the proper systems. ACTION: Refer to the chart to determine the type of oil that is in each service compressor. NOTE: BE SURE TO CHOOSE THE COMPRESSOR THAT HAS THE CORRECT OIL FOR THE SYSTEM BEING SERVICED. NOTE: FS-10 COMPRESSORS BUILT AFTER 9/30/93 ARE NOT FILLED WITH OIL AND HAVE A YELLOW LABEL. THESE COMPRESSORS REQUIRE THE CORRECT AMOUNT OF EITHER MINERAL OIL OR PAG OIL DEPENDING ON THE SYSTEM BEING SERVICED. NOTE: FX-15 SERVICE COMPRESSORS BUILT BEFORE 1/1/93 ARE FILLED WITH MINERAL OIL AND ARE ONLY COMPATIBLE WITH R-12 SYSTEMS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity Refrigerant Oil: All Technical Service Bulletins A/C - Refrigerant Oil Refill Capacity Article No. 97-15-5 07/21/97 AIR CONDITIONING - OIL REFILL CAPACITY CHART - SERVICE TIP FORD: 1994 TEMPO 1994-97 ASPIRE, PROBE, THUNDERBIRD 1994-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-98 CONTOUR LINCOLN-MERCURY: 1994 CAPRI, TOPAZ 1994-97 COUGAR 1994-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1994-96 BRONCO 1994-97 AEROSTAR 1994-98 ECONOLINE, EXPLORER, F-150-350 SERIES, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR ISSUE: This TSB article will provide an easy and quick reference chart for determining the correct amount of refrigerant oil to use when servicing an A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 97-15-5 > May > 97 > A/C - Refrigerant Oil Refill Capacity > Page 5759 ACTION: Refer to Figure 1 to determine how much refrigerant oil is needed to service an A/C system. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 95512 > Mar > 95 > A/C - Adding Refrigerant Oil Service Tip Refrigerant Oil: All Technical Service Bulletins A/C - Adding Refrigerant Oil Service Tip Article No. 95-5-12 03/13/95 AIR CONDITIONING - ADDING REFRIGERANT OIL - SERVICE TIP FORD: 1990-93 FESTIVA 1990-94 TEMPO 1990-95 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-95 ASPIRE LINCOLN-MERCURY: 1990-92 MARK VII 1990-94 TOPAZ 1990-95 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-94 CAPRI 1993-95 MARK VIII MERKUR: 1990 SCORPIO LIGHT TRUCK: 1990 BRONCO II 1990-95 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES, CL-CLT-9000 SERIES 1990-95 CARGO SERIES, F & B SERIES, L SERIES ISSUE: Current repair procedures do not advise on the addition of refrigerant oil to the A/C system when a minor repair is made. ACTION: Add 0.06 L (2 oz) of the proper type new refrigerant oil to the system,. before recharging, when servicing concerns that do not require major component replacement. Repairs considered minor are: O-ring leaks, charge port leaks, Pressure Relief Valve (PRV) leaks, compressor shaft seal leaks, hose leaks, etc. Remember to use polyalkylene glycol (PAG) oil with R-134a systems and mineral oil with R-12 systems. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Oil: > 94156 > Jul > 94 > A/C Compressor - Service Tips Refrigerant Oil: All Technical Service Bulletins A/C Compressor - Service Tips Article No. 94-15-6 07/27/94 AIR CONDITIONING - FS-10 AND FX-15 COMPRESSORS - SERVICE TIPS FORD: 1988-94 CROWN VICTORIA, ESCORT, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 MARK VII 1988-94 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-94 TRACER 1993-94 MARK VIII LIGHT TRUCK: 1988-90 BRONCO II 1988-94 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: FS-10 service compressors built between 1/1/93 and 9/30/93 were built with 7 oz. of oil. These compressors have a white label and are labeled to be compatible with either R-12 or R-134a. These compressors contain either PAG oil or Mineral oil and should be used only in the proper systems. ACTION: Refer to the chart to determine the type of oil that is in each service compressor. NOTE: BE SURE TO CHOOSE THE COMPRESSOR THAT HAS THE CORRECT OIL FOR THE SYSTEM BEING SERVICED. NOTE: FS-10 COMPRESSORS BUILT AFTER 9/30/93 ARE NOT FILLED WITH OIL AND HAVE A YELLOW LABEL. THESE COMPRESSORS REQUIRE THE CORRECT AMOUNT OF EITHER MINERAL OIL OR PAG OIL DEPENDING ON THE SYSTEM BEING SERVICED. NOTE: FX-15 SERVICE COMPRESSORS BUILT BEFORE 1/1/93 ARE FILLED WITH MINERAL OIL AND ARE ONLY COMPATIBLE WITH R-12 SYSTEMS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil System Capacity ......................................................................................................... ......................................................................... 7.0 oz Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 5770 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil Type ............................................................................................................................ ..................................................................... PAG [1] [1] Motorcraft YN-12b or equivalent Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C High Pressure Cutout Switch <--> [High Pressure Sensor / Switch, HVAC] > Component Information > Description and Operation A/C High Pressure Cutout Switch: Description and Operation PURPOSE To protect A/C system from damage by interupting power to the compressor during times of high system pressure. OPERATION The A/C high pressure cutout switch opens at 460-490 psi shutting OFF the A/C compressor. This switch is closed at 230-290 psi and allows compressor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Blower Motor Relay: Locations Power Distribution Box The Blower Motor Relay is mounted in the power distribution box, at RH fender apron. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 5779 Blower Motor Relay: Description and Operation PURPOSE To provide current to operate the heater-A/C blower motor. OPERATION When the Blower Motor Relay is energized, relay contact closes and completes circuit for blower motor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation Compressor Clutch Relay: Description and Operation PURPOSE When the vehicle operator goes to Wide Open Throttle (WOT), the Wide Open Throttle A/C (WOT A/C) relay opens, suspending A/C operation until normal vehicle operation resumes. This is done to allow maximum power to the drive wheels under heavy acceleration or load. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations Ambient Temperature Sensor: Locations Limited Edition And Electronic Group The Ambient Temperature Sensor is located at the left front of engine compartment, in front of radiator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor <--> [Ambient Temperature Sensor / Switch HVAC] > Component Information > Locations > Page 5787 Ambient Temperature Sensor: Description and Operation PURPOSE The Ambient Temperature Sensor is used by the air conditioning system to determine the outside air temperature. OPERATION The Ambient Temperature Sensor sends a signal to overhead console to indicate outside air temperature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > With Air Conditioning > Page 5792 Heater-A/C Control Assembly (Blower Motor) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 5793 Blower Motor Switch: Description and Operation PURPOSE The Blower Switch allows the driver to select LO, MED LO, MED HI or HI blower motor speed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Diagrams > Page 5794 Blower Motor Switch: Testing and Inspection Component Testing Procedure Schematic Terminal ID Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C High Pressure Cutout Switch <--> [High Pressure Sensor / Switch, HVAC] > Component Information > Description and Operation A/C High Pressure Cutout Switch: Description and Operation PURPOSE To protect A/C system from damage by interupting power to the compressor during times of high system pressure. OPERATION The A/C high pressure cutout switch opens at 460-490 psi shutting OFF the A/C compressor. This switch is closed at 230-290 psi and allows compressor operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations Service Port HVAC: Locations The high pressure service port is located on the A/C compressor to condenser discharge line. The low pressure service port is located in the evaporator to compressor suction line. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page 5802 Service Port HVAC: Description and Operation The A/C service port valves on R-134a systems are of the one-piece design. The top portion of the fitting is aluminum and is threaded into a steel body on the suction accumulator/drier or on the refrigerant line and sealed with an O-ring. Two special service tools have been developed to aid in servicing of the access gauge port valves. They are the high side A/C fitting socket tool No. D94L-19703-A, or equivalent and low side A/C fitting socket tool No. D94L-19703-B, or equivalent. The high side fitting is the largest of the two valves. Both valves require special adapters to attach service equipment to the A/C system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 95614 > Mar > 95 > Heater - Air Flow With System in the Off Mode Vacuum Check Valve HVAC: Customer Interest Heater - Air Flow With System in the Off Mode Article No. 95-6-14 03/27/95 HEATER - OBJECTIONABLE AIRFLOW FROM PANEL REGISTERS DURING HEAVY ACCELERATION - NON-A/C VEHICLES LIGHT TRUCK: 1993-94 EXPLORER, RANGER ISSUE: Objectionable airflow from the heater system panel registers may occur when the system is in the OFF mode and the vehicle is under heavy acceleration. This condition is caused by movement of the fresh air door when the vacuum to the door actuator is lost during heavy acceleration or other low engine vacuum conditions. ACTION: Installation of a vacuum hose/reservoir/check valve assembly will provide sufficient vacuum level to maintain the heater system fresh air door in the closed position. Refer to the following procedure for service details. SERVICE PROCEDURE 1. Remove the blower assembly from the vehicle. 2. Drill two (2) holes in the blower assembly, in a vertical position, to allow for installation of the vacuum reservoir. Refer to Figure 1. 3. Using two (2) screws (389915-S2), mount the vacuum reservoir (F4Tz-19A566-A) as shown in Figure 1. 4. Disconnect the existing vacuum check valve from the engine vacuum harness and the main wiring harness. 5. Reinstall the blower assembly in the vehicle. 6. Attach the vacuum hose in the wire harness to the new check valve included with the vacuum reservoir. 7. Remove the inline connector to the "T" in the engine vacuum harness. 8. Attach the check valve to the engine vacuum harness with the vacuum hose and inline connector provided on the assembly. 9. Start the engine and verify proper operation of the Fresh Air/Off door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 95614 > Mar > 95 > Heater - Air Flow With System in the Off Mode > Page 5811 PART NUMBER PART NAME F4TZ-19A566-A Vacuum Reservoir Assembly 389915-52 Screw OTHER APPLICABLE ARTICLES: 94-4-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 95O614A Install Vacuum Reservoir 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19A566 79 OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95614 > Mar > 95 > Heater - Air Flow With System in the Off Mode Vacuum Check Valve HVAC: All Technical Service Bulletins Heater - Air Flow With System in the Off Mode Article No. 95-6-14 03/27/95 HEATER - OBJECTIONABLE AIRFLOW FROM PANEL REGISTERS DURING HEAVY ACCELERATION - NON-A/C VEHICLES LIGHT TRUCK: 1993-94 EXPLORER, RANGER ISSUE: Objectionable airflow from the heater system panel registers may occur when the system is in the OFF mode and the vehicle is under heavy acceleration. This condition is caused by movement of the fresh air door when the vacuum to the door actuator is lost during heavy acceleration or other low engine vacuum conditions. ACTION: Installation of a vacuum hose/reservoir/check valve assembly will provide sufficient vacuum level to maintain the heater system fresh air door in the closed position. Refer to the following procedure for service details. SERVICE PROCEDURE 1. Remove the blower assembly from the vehicle. 2. Drill two (2) holes in the blower assembly, in a vertical position, to allow for installation of the vacuum reservoir. Refer to Figure 1. 3. Using two (2) screws (389915-S2), mount the vacuum reservoir (F4Tz-19A566-A) as shown in Figure 1. 4. Disconnect the existing vacuum check valve from the engine vacuum harness and the main wiring harness. 5. Reinstall the blower assembly in the vehicle. 6. Attach the vacuum hose in the wire harness to the new check valve included with the vacuum reservoir. 7. Remove the inline connector to the "T" in the engine vacuum harness. 8. Attach the check valve to the engine vacuum harness with the vacuum hose and inline connector provided on the assembly. 9. Start the engine and verify proper operation of the Fresh Air/Off door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95614 > Mar > 95 > Heater - Air Flow With System in the Off Mode > Page 5817 PART NUMBER PART NAME F4TZ-19A566-A Vacuum Reservoir Assembly 389915-52 Screw OTHER APPLICABLE ARTICLES: 94-4-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 95O614A Install Vacuum Reservoir 0.6 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19A566 79 OASIS CODES: 208000, 208300, 208999 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve HVAC: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise Wiper Pivot: All Technical Service Bulletins Blower Motor - Burning Odor/Smoke/Rustling Noise Article No. 99-20-6 10/04/99 ^ AIR CONDITIONING - BURNING ODOR OR SMOKE WHILE BLOWER MOTOR IS ON ^ NOISE - "RUSTLING" HEARD ALONG WITH AN ODOR WHILE BLOWER MOTOR IS ON FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER This TSB article is being republished in its entirety to change the Causal Part number. ISSUE A burning odor or smoke, and/or "rustling" noise may occur when the blower motor is running if leaves or foreign material enter the blower case. Noise complaints may result from debris coming in contact with the blower fan. In some cases, the debris may also come in contact with the blower motor resistor which may be hot enough to cause a burning odor or smoke. ACTION Clean the debris out of the blower case and install foam grommets around the wiper pivots to seal out further debris from entering the system. Refer to the following Service Procedure for details. SERVICE PROCEDURE ALL MODEL YEARS - CLEAN DEBRIS FROM THE HEATER CASE 1. Remove blower motor (refer to the appropriate Service or Workshop Manual for procedure). 2. Remove blower motor resistor. NOTE BE CAREFUL NOT TO DAMAGE OR BEND RESISTOR COILS WHICH COULD RESULT IN AN ELECTRICAL SHORT. 3. Clean the blower motor, motor cooling tube, blower housing, resistor, and inlet duct of all debris. 4. Reinstall resistor. 5. Reinstall blower motor. 1991-1994 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve HVAC: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5823 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve HVAC: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5824 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve HVAC: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5830 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Check Valve HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Vacuum Check Valve HVAC: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 5831 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Description and Operation Vacuum Harness HVAC: Description and Operation DESCRIPTION Engine vacuum systems are currently installed as a pre-assembled color coded type of harness. The colorings act as a visual aid both during production and during service. Nylon Vacuum Harness Tubing And Connectors CONSTRUCTION The vacuum hose harness consist of colored nylon tubing (0.15" o.d. and 0.09" i.d.) bonded to nylon or rubber connectors. A rubber insert is installed in the end of the nylon connectors to provide a secure fitting seal at the components nipple connection. Occasionally, rubber hosing (5/32" or 7/32") may used within the harness to replace a damaged nylon vacuum tube. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation Vacuum Tank: Description and Operation Vacuum Reservoirs PURPOSE The Vacuum Reservoir temporarily stores vacuum until it is needed. This temporary vacuum storage helps to prevent rapid fluctuations and/or sudden drops in a vacuum signal line, as when an engine is under load or during acceleration. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation > Page 5838 Vacuum Tank: Testing and Inspection Vacuum Reservoirs Apply initial vacuum of 15 to 20". Vacuum loss should not exceed 0.5" in 60 seconds. If it does, replace the reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly <--> [Clockspring Assembly / Spiral Cable, Air Bag] > Component Information > Description and Operation Clockspring Assembly: Description and Operation Steering Column Wheel and Air Bag Sliding Contact The air bag sliding contact is mounted on the steering column, behind the steering wheel. The air bag sliding contact carries electrical signals from the steering column wire harness through the contact in the steering wheel to the driver side air bag module, horn, and speed control if equipped. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation Tone Generator The air bag indicator is the prime means of determining the supplemental air bag restraint system status. However, if the air bag indicator is inoperative and system fault exists, a tone will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be serviced before further diagnosing and testing can be completed. Unless serviced, the supplemental air bag restraint system may not function properly in the event of an accident. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Specifications Child Seat Tether Attachment: Specifications Tether Attachment Bolt ........................................................................................................................ ........................................... 22-34 N.m (16-25 Lb-Ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Specifications > Page 5858 Child Seat Tether Attachment: Service Precautions WARNING: WHEN USING ANY INFANT OR CHILD RESTRAINT SYSTEM, IT IS IMPORTANT THAT YOU FOLLOW THE INSTRUCTIONS PROVIDED BY THE MANUFACTURER CONCERNING ITS INSTALLATION AND USE. FAILURE TO FOLLOW EACH OF THE RESTRAINT MANUFACTURER'S INSTRUCTIONS CAN RESULT IN A CHILD STRIKING THE VEHICLE'S INTERIOR DURING A SUDDEN STOP OR COLLISION. WARNING: IT IS IMPORTANT THAT THE TETHER BOLT/ANCHOR BE SECURELY TIGHTENED TO SPECIFICATION. OTHERWISE, THE CHILD'S SAFETY SEAT MAY NOT BE PROPERLY SECURED AND THE CHILD COULD BE INJURED IN CASE OF A SUDDEN STOP OR COLLISION. WARNING: ALWAYS KEEP THE BUCKLE RELEASE BUTTON POINTING UPWARD AND AWAY FROM THE CHILD SAFETY SEAT, WITH THE TONGUE BETWEEN THE CHILD SAFETY SEAT AND THE RELEASE BUTTON. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN ACCIDENTAL UNBUCKLING OF THE SAFETY BELT IF THE CHILD SAFETY SEAT HITS THE RELEASE BUTTON. RELEASE OF THE SAFETY BELT COULD RESULT IN SERIOUS INJURIES. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Safety Seat Tether Attachment Child Seat Tether Attachment: Description and Operation Child Safety Seat Tether Attachment Some manufacturers make safety seats with a tether strap that goes over the back of the vehicle seat and attaches to an anchoring point behind the vehicle seat. Ford recommends the placement of tethered safety seats in a rear seating position with the tether strap attached to the tether anchoring point. The right front seating position may be used if it is the only seating position available. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Safety Seat Tether Attachment > Page 5861 Child Seat Tether Attachment: Description and Operation Child Seat Locking Clip The locking clip must be used to secure a child seat when the vehicle has a shoulder and lap belt with a sliding tongue. Every safety belt that requires a locking clip is identified on the belt with a label shown in the following illustration. The locking clip is installed on a sample piece of webbing to show proper installation. WARNING: IF YOU DO NOT USE A LOCKING CLIP, INJURIES COULD RESULT FROM THE CHILD SEAT TIPPING OVER DURING NORMAL BRAKING OR CORNERING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Tether Attachment Bolt ........................................................................................................................ ........................................... 22-34 N.m (16-25 Lb-Ft) Safety Belt Attaching Bolts .............................. ................................................................................................................................30-40 N.m (22-30 Lb-Ft) Slide Bar Bolt ............................................................................................................................ ........................................................... 7-9.5 N.m (5-7 Lb-Ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 5865 Seat Belt: Description and Operation Continuous-Loop System The front outboard safety belt is a continuous-loop system. The outboard combination lap and shoulder belts use a common sliding tongue. To secure the belts, the tongue is inserted into the inboard buckle. The webbing for the lap belt is anchored inboard to the floor pan. The shoulder safety belt retractor is designed to let the webbing freely move In or out at all times, except during hard braking, hard cornering or impacts of approximately 5 mph (8 km/h) or more, when it is automatically locked by a mechanically actuated inertia sensor. Fastening Safety Belts After entering the vehicles, adjust the front seat to obtain the best position for driving comfort, access to controls and visibility. Then, use the following procedure for fastening safety belts. WARNING: USE THE SHOULDER BELT ON THE OUTSIDE SHOULDER ONLY. NEVER WEAR THE SHOULDER BELT UNDER THE ARM. NEVER SWING IT AROUND YOUR NECK OVER THE INSIDE SHOULDER. NEVER USE A SINGLE BELT FOR MORE THAN ONE PERSON MAKE SURE THE LAP PORTION OF THE BELT IS FITTED SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS, NOT ON THE WAIST. FAILURE To FOLLOW THESE PRECAUTIONS COULD INCREASE THE CHANCE AND/OR SEVERITY OF INJURY IN A COLLISION. 1. Before fastening combination lap/shoulder safety belt, It may be necessary to lengthen it. NOTE: If you grasp the tongue by the tongue cover while attempting to lengthen the belt, you may find it somewhat difficult to slide the tongue along the webbing because the tongue's mechanism is grabbing the webbing. 2. To lengthen tie belt, pull some webbing out of the refractor. While holding the webbing below the tongue, grasp the tip (rectal portion) of the tongue (not the tongue cover). Then, while keeping the rectal portion 01, the tongue parallel to the webbing. slide the tongue upward. 3. To fasten the belt, pull the lap/shoulder belt from the retractor so that the shoulder portion of the belt crosses your shoulder and chest. Be sure the belt is not twisted. If it is, remove the twist. Insert the bell tongue into the proper buckle for that seating position until you hear a "snap" and feel it latch. Make sure the tongue is securely fastened to the buckle. 4. To tighten the lap portion of the belt pull upon the shoulder belt until it fits snugly. The belt should rest as low on the hips as possible. 5. Pull the lap/shoulder belt from the rear safety belt retractor and tongue so the shoulder portion of the safety belt crosses the shoulder and chest. Insert the belt tongue into the proper buckle until a snap is heard and the rear safety belt is latched. Pull up on the shoulder portion of the rear safety belt to tighten the lap portion to a snug fit. Make sure the rear safety bell is as low on the hips as possible. 6. The rear safety belt system allows freedom of movement, locking only on hard braking or impacts of approximately 8 km/h (5 mph) or more. The system cannot be made to lock by jerking on the rear safety belt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications > Page 5866 Seat Belt: Testing and Inspection 1. Driver will buckle up and proceed to a sate test area. If RH front or rear passenger safety belt must be tested, a passenger should be buckled into RH front or rear seat. (The RH front belt may be tested using a driver only, providing driver has the ability to grasp RH front shoulder belt and extend it approximately 66 cm [26 inches] with no compromise to safe driving). This method applies to 8 km/h (5 mph) test only. 2. After reaching a safe area to perform sudden stops, driver will attain a speed of approximately 8 km/h (5 mph). The driver should inform passenger (if applicable) that he is preparing to make a severe brake application. At this time, both driver and passenger should grasp their respective shoulder harnesses and prepare to lean slightly forward at the moment brake application is made. 3. The driver will make a maximum brake application without tire skid. (The maximum brake application should be on dry concrete or equivalent hard road surface; never on a wet or gravel road.) WARNING: THE DRIVER AND PASSENGER MUST BE PREPARED TO BRACE THEMSELVES IN THE EVENT THE RETRACTOR DOES NOT LOCK. 4. The driver and passenger should lean forward slightly into shoulder harness. At this instant, belts should lock up without webbing payout. 5. If there is a lockup of both shoulder straps, safety belt assemblies are functioning properly. NOTE: If the retractor of a new safety belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, reshape the sheet metal and install another new complete safety belt assembly. 6. Should either or both retractors fail to lock up at the 8 km/h (5 mph) speed, repeat the test at a constant 24 km/h (15 mph). (This test must be performed with RH front or rear passenger if RH front or rear belts are to be tested.) 7. If either or both shoulder safety belts do not lock up at 24 km/h (15 mph) test, return vehicle for service of malfunctioning safety belts. Remove retractor and rework sheet metal in retractor's mounting surface. Install retractor assembly and retest safety belt assembly(s) as previously stated. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Adjustments > Fastening Safety Belts Seat Belt: Adjustments Fastening Safety Belts Fastening Safety Belts After entering the vehicles, adjust the front seat to obtain the best position for driving comfort, access to controls and visibility. Then, use the following procedure for fastening safety belts. WARNING: USE THE SHOULDER BELT ON THE OUTSIDE SHOULDER ONLY. NEVER WEAR THE SHOULDER BELT UNDER THE ARM. NEVER SWING IT AROUND YOUR NECK OVER THE INSIDE SHOULDER. NEVER USE A SINGLE BELT FOR MORE THAN ONE PERSON MAKE SURE THE LAP PORTION OF THE BELT IS FITTED SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS, NOT ON THE WAIST. FAILURE To FOLLOW THESE PRECAUTIONS COULD INCREASE THE CHANCE AND/OR SEVERITY OF INJURY IN A COLLISION. 1. Before fastening combination lap/shoulder safety belt, It may be necessary to lengthen it. NOTE: If you grasp the tongue by the tongue cover while attempting to lengthen the belt, you may find it somewhat difficult to slide the tongue along the webbing because the tongue's mechanism is grabbing the webbing. 2. To lengthen tie belt, pull some webbing out of the refractor. While holding the webbing below the tongue, grasp the tip (rectal portion) of the tongue (not the tongue cover). Then, while keeping the rectal portion 01, the tongue parallel to the webbing. slide the tongue upward. 3. To fasten the belt, pull the lap/shoulder belt from the retractor so that the shoulder portion of the belt crosses your shoulder and chest. Be sure the belt is not twisted. If it is, remove the twist. Insert the bell tongue into the proper buckle for that seating position until you hear a "snap" and feel it latch. Make sure the tongue is securely fastened to the buckle. 4. To tighten the lap portion of the belt pull upon the shoulder belt until it fits snugly. The belt should rest as low on the hips as possible. 5. Pull the lap/shoulder belt from the rear safety belt retractor and tongue so the shoulder portion of the safety belt crosses the shoulder and chest. Insert the belt tongue into the proper buckle until a snap is heard and the rear safety belt is latched. Pull up on the shoulder portion of the rear safety belt to tighten the lap portion to a snug fit. Make sure the rear safety bell is as low on the hips as possible. 6. The rear safety belt system allows freedom of movement, locking only on hard braking or impacts of approximately 8 km/h (5 mph) or more. The system cannot be made to lock by jerking on the rear safety belt. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Adjustments > Fastening Safety Belts > Page 5869 Seat Belt: Adjustments Lap Portion WARNING: EACH SEATING POSITION IN THE VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH CONSISTS OF ONE BUCKLE AND ONE TONGUE. THE SAFETY BELT ASSEMBLY IS DESIGNED TO BE USED AS A PAIR AND IS NOT TO BE USED ACROSS SEATING POSITION. MAKE SURE THE LAP PORTION OF THE BELT IS FITTED SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS, NOT AROUND THE WAIST. FAILURE TO DO SO MAY INCREASE THE CHANCE OF INJURY IN THE EVENT OF A COLLISION. On outboard lap/shoulder safety belts, pull up on the shoulder portion of the belt to tighten the lap portion to a snug fit. Make sure the belt is as low on hips as possible. Center rear safety belts are equipped with manually adjusted lap belts for rear center seat occupants. Insert the rear safety belt tongue into the proper buckle until a snap is heard. Pull on both sides of rear safety belt to ensure the buckle is latched. Pull up on the end of the rear safety belt to tighten the lap portion to a snug fit. Make sure rear safety belt is as low on the hips as possible. WARNING: IF THE SHOULDER BELT IS OFF YOUR SHOULDER OR ON YOUR UPPER ARM, THERE IS A GREATER RISK OF SEVERE INJURY IN A COLLISION. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Adjustments > Fastening Safety Belts > Page 5870 Seat Belt: Adjustments Shoulder Portion The shoulder restraint portion of the safety belt adjusts automatically to a snug position. WARNING: DO NOT INTRODUCE SLACK INTO THE SAFETY BELT SYSTEM BECAUSE THE BELT LOCKS UPON IMPACT WHERE IT IS POSITIONED. USE THE SHOULDER SAFETY BELT ON THE OUTSIDE SHOULDER ONLY. NEVER WEAR THE SHOULDER SAFETY BELT UNDER THE ARM. NEVER SWING IT AROUND THE NECK OVER THE INSIDE SHOULDER. NEVER USE A SINGLE BELT FOR MORE THAN ONE PERSON. ENSURE THE LAP PORTION OF THE BELT IS FITTED SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS, NOT ON THE WAIST. FAILURE TO FOLLOW THESE PRECAUTIONS COULD INCREASE THE CHANCE AND/OR SEVERITY OF INJURY IN A COLLISION. After unbuckling the safety belt, it is recommended that care is taken during retraction to prevent it from striking other passengers, or hitting trim panels or painted door surfaces. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection Safety Belt Maintenance WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF SO EQUIPPED AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND A QUALIFIED TECHNICIAN FINDS THAT THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Safety belt assemblies should be periodically inspected to ensure that they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install new safety belt(s) using the appropriate instructions. Perform Functional Test Procedure. Safety Belt Webbing WARNING: DO NOT BLEACH OR DYE THE WEBBING, AS WEBBING MAY WEAKEN. Clean the safety belt webbing with a mild soap solution recommended for cleaning upholstery or carpets; follow instructions provided with soap. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5873 Seat Belt: Service and Repair Removal and Installation Front Safety Belt Buckle and Inboard Slide Bar Removal NOTE: If the slide bar is being replaced, check for service part no. identification sticker on the sleeve or collar of the new replacement slide bar assembly and remove the sticker and any adhesive residue before installing the slide bar assembly to the seat cushion assembly. 1. Move seat forward and remove bolt attaching slide bar to front floor pan. 2. Disconnect electrical connection to safety belt switch. 3. Remove front seat and track. 4. Remove slide bar collar bolt from seat cushion bracket. 5. Remove nut attaching slide bar to support bracket, located at front end of seat track. 6. Remove slide bar from seat. NOTE: Clamp the collar of slide bar into vise along the break line only. 7. Clamp slide bar into vise. 8. Remove bolt retaining the safety belt buckle assembly to the slide bar. Installation 1. Align slot in the safety belt buckle anchor with anti-rotation tabs on the slide bar. 2. Install safety belt buckle attaching bolt. Tighten to 30-40 N.m (22-30 ft-lb). NOTE: Slide bar must be positioned over stud of the mounting bracket attached to the seat track assembly. 3. Position slide bar assembly to the seat cushion. NOTE: The slide bar must be able to move easily forward and rearward prior to installation of seat. 4. Loosely install nut required to retain front end of slide bar to support bracket, located at front seat track. Tighten nut but do not allow to contact plastic sleeve on slide bar. 5. Secure bolt retaining slide bar collar to seat cushion bracket. Tighten bolt to 7-9.5 N.m (5-7 ft-lb). 6. Position the seat assembly in the vehicle. Install the retaining screws required to retain the seat tracks to the floor as follows: - Hand start the front and rear seat track-to-floor retaining screws. - To make sure the seat tracks will be synchronized, first torque the front attachments to 12-23 N.m (9-17 ft-lb). - Torque the rear attachments to 19-26 N.m (14-19 ft-lb). 7. Align the rear attaching hole in the slide bar assembly with the attaching hole in the floor. Be sure the rubber spacer is in place between the slide bar and the floor attachment. 8. Position the slide bar boot to the slide bar assembly. Then install the Torx(R) retaining bolt through the boot, slide bar, rubber spacer, and into the weld nut provided in the floor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5874 9. Hand start the retaining bolt into the weld nut. Rotate the slide bar boot enough to allow the head of the Torx(R) retaining bolt to be seen. 10. Pull the slide bar against the head of the bolt. If the slide bar is not against the bolt head, it may be possible for the shoulder of the bolt to "bottom out" on the slide bar, resulting in the slide bar not being in required alignment. 11. Torque the retaining Torx(R) bolt to 30-40 N.m (22-30 ft-lb). 12. Connect the electrical connector for the safety belt buckle switch (driver's seat only). 13. Check restraint system for proper operation. Inboard Front Safety Belts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5875 SPECIAL SERVICE TOOL(S) REQUIRED Description ...................................................................... ................................................................................................................................ Tool Number Safety Belt Bolt Bit (#60 Torx(R)) ........................................................................................................ ........................................................... T77L-2100-A Remove the bolts securing the front seat center passenger belt and front safety belt buckle end to front floor pan (one each side). Remove front seat center passenger belt and front safety belt buckle end from vehicle. For installation, follow removal procedures in reverse order. Tighten bolt to 30-40 N.m (22-30 ft-lb). - Check the restraint system for proper operation. - Cable must wrap around front crossmember. - Check sealer around floor anchor bolt hole and add Ford Caulking Cord D6AZ-19569-A (ESB-M4G32-A) or equivalent. Outboard Front Safety Belts Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5876 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5877 SPECIAL SERVICE TOOL(S) REQUIRED Description ........................................................................................................................................... ........................................................... Tool Number Safety Belt Bolt Bit (#80 Torx(R)) ........................................................................................................ ........................................................... T77L-2100-A 1. Remove front seat shoulder strap guide cover and remove the bolt. 2. Lift floor carpet and remove bolt retaining floor anchor to front floor pan. 3. Remove quarter trim panel. 4. Remove the screw retaining the belt loop to the sheet metal (two-door models only). 5. Remove the bolt retaining the front safety belt retractor and tongue. 6. Remove front safety belt retractor and tongue from the vehicle. Installation 1. Position front safety belt retractor and tongue to the vehicle and install the retaining bolt. Tighten to 30-40 N.m (22-30 ft-lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5878 2. Position the belt loop to the vehicle and install the retaining screw (two-door only). 3. Feed the floor anchor end of the front safety belt retractor and tongue through the quarter trim panel. Install quarter trim panel. 4. Position the floor anchor anti-rotation tab to the front floor pan. Install the bolt and tighten to 30-40 N.m (22-30 ft-lb). 5. Position safety belt guide. Install bolt and tighten to 30-40 N.m (22-30 ft-lb). 6. Install front seat shoulder strap guide cover. 7. Check the restraint system for proper operation. Rear Safety Belts, Inboard NOTE: Safety belt BUCKLES, center adjust tongues and belt and retractors can be replaced separately. However, if a safety belt assembly was in use during a collision, the belt and retractor must be replaced as well as the center adjust tongue and belt and buckle assembly or the center adjust tongue and the cable and BUCKLE assembly. When replacing safety belt and BUCKLE, safety cable and BUCKLE, center adjust tongues and belt and retractors, use only the replacement parts specified in the Ford Master Parts Catalogs for the make and model of the vehicle being serviced. Safety belt assemblies must not be interchanged between vehicle models. Removal 1. Remove the bolts securing the rear safety belt and buckle to rear floor. 2. Remove rear safety belt and buckles from vehicle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5879 Installation 1. Position rear safety belt and buckles to rear floor and secure with bolt. Tighten to 30-40 N.m (22-30 ft-lb). 2. Check the restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5880 Seat Belt: Service and Repair Service Procedures Post Collision Inspection WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), IF SO EQUIPPED, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Repair Notes WARNING: ALL OUTBOARD SAFETY BELT ASSEMBLIES INCLUDING FRONT SAFETY BELT RETRACTOR AND TONGUES AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND A QUALIFIED TECHNICIAN FINDS THAT THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. The safety seat belts and shoulder belts are factory-installed in their proper locations. If the safety belts or shoulder belts are removed for any reason, they should be reinstalled according to factory design specifications. When replacing safety belts and/or retractor assemblies, use only the replacement parts specified in the Ford Parts and Service Division Master Parts and Accessories Catalogs for the vehicle being serviced. Use Safety Belt Bolt Bit T77L-2100-A (#50 Torx(R)) to remove or install all safety belt assembly anchorage bolts. Upon installation, tighten the anchor bolts to 33-40 N.m (22-30 ft-lb). Safety Belt Tongue Rotated on Belt Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5881 1. Grasp the belt tongue and pull down on the belt webbing closest to you to form a loop through the upper (narrow and longer) slot in the tongue. 2. Working within the upper slot, rotate and fold the belt webbing over itself as required to remove the twist. 3. Pull the excess belt webbing back through the upper slot in the tongue. 4. Repeat the above steps to complete the removal of the twist at the lower (wider and larger) slot in the tongue. 5. When completed, the safety belt should look like the above illustration. Safety Belt Twisted at Safety Belt Guide Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5882 NOTE: These procedures affect both wire formed and stamped safety belt guide (D-ring) designs. 1. Grasp the belt webbing at the safety belt guide (D-ring). 2. Rotate and fold the belt webbing over itself as required to remove the twist. 3. Feed folded portion of belt through safety belt guide (D-ring). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 5883 4. When completed, safety belt should look like the following. Seat Belt With Anchor Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchor plate with a 27/64-inch drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat belt). 4. Blow out the chips. 5. Install the attachment parts in the order shown, whichever is applicable. Tighten the replacement bolt to 30-40 N.m (22-30 ft-lb). Original parts are to be replaced with the repair parts. Unless specified in the guides, use original parts. 6. When repairing a multiple belt and attachment, install nut to the bolt in the tunnel area from the underside of the floorpan. Tighten to specification 30-40 N.m (22-30 ft-lb). Seat Belt Without Anchor Plate Thread Damage 1. Remove the damaged bolt for the anchor reinforcement and discard. 2. Install a new bolt with the same part number as indicated under Specifications. Tighten to 30-40 N.m (22-30 ft-lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Page 5884 Seat Belt: Tools and Equipment Description ........................................................................................................................................... ........................................................... Tool Number Safety Belt Bolt Bit (#50 Torx(R)) ........................................................................................................ ........................................................... T77L-2100-A Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Slide Bar Bolt ....................................................................................................................................... ................................................ 7-9.5 N.m (5-7 Lb-Ft) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 5888 Seat Belt Buckle: Service and Repair Removal NOTE: If the slide bar is being replaced, check for service part no. identification sticker on the sleeve or collar of the new replacement slide bar assembly and remove the sticker and any adhesive residue before installing the slide bar assembly to the seat cushion assembly. 1. Move seat forward and remove bolt attaching slide bar to front floor pan. 2. Disconnect electrical connection to safety belt switch. 3. Remove front seat and track. 4. Remove slide bar collar bolt from seat cushion bracket. 5. Remove nut attaching slide bar to support bracket, located at front end of seat track. 6. Remove slide bar from seat. NOTE: Clamp the collar of slide bar into vise along the break line only. 7. Clamp slide bar into vise. 8. Remove bolt retaining the safety belt buckle assembly to the slide bar. Installation 1. Align slot in the safety belt buckle anchor with anti-rotation tabs on the slide bar. 2. Install safety belt buckle attaching bolt. Tighten to 30-40 N.m (22-30 ft-lb). NOTE: Slide bar must be positioned over stud of the mounting bracket attached to the seat track assembly. 3. Position slide bar assembly to the seat cushion. NOTE: The slide bar must be able to move easily forward and rearward prior to installation of seat. 4. Loosely install nut required to retain front end of slide bar to support bracket, located at front seat track. Tighten nut but do not allow to contact plastic sleeve on slide bar. 5. Secure bolt retaining slide bar collar to seat cushion bracket. Tighten bolt to 7-9.5 N.m (5-7 ft-lb). 6. Position the seat assembly in the vehicle. Install the retaining screws required to retain the seat tracks to the floor as follows: - Hand start the front and rear seat track-to-floor retaining screws. - To make sure the seat tracks will be synchronized, first torque the front attachments to 12-23 N.m (9-17 ft-lb). - Torque the rear attachments to 19-26 N.m (14-19 ft-lb). 7. Align the rear attaching hole in the slide bar assembly with the attaching hole in the floor. Be sure the rubber spacer is in place between the slide bar and the floor attachment. 8. Position the slide bar boot to the slide bar assembly. Then install the Torx(R) retaining bolt through the boot, slide bar, rubber spacer, and into the weld nut provided in the floor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications > Page 5889 9. Hand start the retaining bolt into the weld nut. Rotate the slide bar boot enough to allow the head of the Torx(R) retaining bolt to be seen. 10. Pull the slide bar against the head of the bolt. If the slide bar is not against the bolt head, it may be possible for the shoulder of the bolt to "bottom out" on the slide bar, resulting in the slide bar not being in required alignment. 11. Torque the retaining Torx(R) bolt to 30-40 N.m (22-30 ft-lb). 12. Connect the electrical connector for the safety belt buckle switch (driver's seat only). 13. Check restraint system for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation For some people, the safety belt may be too short even when it is fully extended. You can add about eight inches (20 cm) to the belt length with a safety belt extension assembly. Safety belt extensions are available from your dealer. The safety belt extension assembly is only available with black webbing and standard buckle and must be of the same manufacture as the belt system to which it is attached. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Controller Module: Locations Component Locations The Anti-Theft Controller Module is located at the left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 5898 Anti-Theft Controller Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 5899 Anti-Theft Controller Module: Description and Operation PURPOSE The Anti-Theft Controller Module controls the vehicle antitheft system through inputs from door, hood, and shock sensors. OPERATION If the anti-theft system is triggered, the starter circuit will be disabled. The module monitors switches located throughout vehicle and if triggered, sounds horn and flashes headlamps and parking lamps at an intermittent rate of 80 cycles per minute. Also disables starting system until anti-theft is disarmed. Senses a 12V signal to arm or disarm the anti-theft system when doors are locked or unlocked by remote transmitter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5904 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5905 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 5906 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations The Program Connector is located under the LH access panel, taped to the wiring harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5918 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5919 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5920 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5926 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5927 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 5928 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 5929 Keyless Entry Transmitter: Service and Repair Before any of the REMOTE features will operate, the RKE module must be programmed to accept signals from the transmitters. The RKE module may be programmed to accept signals from up to four transmitters. The following steps must be performed in order to program or reprogram the RKE module to respond to the selected transmitters. 1. Put the ignition switch in "RUN" or "ACC" and momentarily jumper the two program connector terminals located under LH quarter access panel. The system will respond by locking and then unlocking all doors. 2. Press any button on the transmitter. All doors will lock and then unlock to verify transmitter signal acceptance. 3. Repeat step 2 in order to program the RKE module to accept up to four transmitter signals. 4. Turn the ignition switch to "OFF". All doors will then lock and unlock. 5. Operate a button on each transmitter to verify that the system has been programmed successfully. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Memory Seat Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 5934 Seat Memory Switch: Description and Operation PURPOSE The Memory Seat Switch is used to recall one of two previously recorded seat positions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier <--> [Amplifier, Sound System] > Component Information > Diagrams Amplifier: Diagrams Premium And Highline Sound Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier <--> [Amplifier, Sound System] > Component Information > Diagrams > Page 5939 Premium And Highline Sound Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5949 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5950 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5951 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5952 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5953 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5954 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5955 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5961 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5962 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5963 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5964 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5965 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5966 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5967 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5976 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5977 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5978 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5979 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5980 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5981 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 5982 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5988 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5989 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5990 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5991 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5992 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5993 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 5994 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speaker: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Compass: All Technical Service Bulletins Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations Anti-Theft Controller Module: Locations Component Locations The Anti-Theft Controller Module is located at the left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 6009 Anti-Theft Controller Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Anti-Theft Controller Module <--> [Alarm Module, (Vehicle Antitheft)] > Component Information > Locations > Page 6010 Anti-Theft Controller Module: Description and Operation PURPOSE The Anti-Theft Controller Module controls the vehicle antitheft system through inputs from door, hood, and shock sensors. OPERATION If the anti-theft system is triggered, the starter circuit will be disabled. The module monitors switches located throughout vehicle and if triggered, sounds horn and flashes headlamps and parking lamps at an intermittent rate of 80 cycles per minute. Also disables starting system until anti-theft is disarmed. Senses a 12V signal to arm or disarm the anti-theft system when doors are locked or unlocked by remote transmitter. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6014 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6015 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 6016 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines Towing Information: Technical Service Bulletins Vehicle - Towing Behind RVs Guidelines Article No. 98-5A-12 03/18/98 ^ BRAKES - WEIGHT LIMITATIONS FOR TOWING ^ RECREATIONAL VEHICLES - WEIGHT RATINGS FOR UNBRAKED TOWING LESS THAN GROSS COMBINATION WEIGHT RATING (GCWR) ^ TOWING BEHIND RECREATIONAL VEHICLES - RECOMMENDED GUIDELINES ^ TRANSAXLE/TRANSMISSION/TRANSFER CASE - VEHICLES TOWED BEHIND RECREATIONAL VEHICLES - RECOMMENDED TOWING GUIDELINES FORD: 1988-93 FESTIVA 1988-94 TEMPO 1989-96 PROBE, TAURUS SHO 1991-97 ESCORT 1994-96 ASPIRE LINCOLN-MERCURY: 1988-94 TOPAZ 1991-94 CAPRI 1991-97 TRACER LIGHT TRUCK: 1988-96 AEROSTAR, BRONCO, E-350, F SUPER DUTY, F-250, F-350, F-53 MOTORHOME, RANGER 1988-97 F-150 1991-96 EXPLORER 1997 MOUNTAINEER ISSUE: Many motorhome owners tow a vehicle when traveling. Improper techniques can "overload" the brake system of the tow vehicle or damage the drivetrain of the vehicle being towed. ACTION: Use the information and charts shown in this TSB article to properly match tow vehicle, towed vehicle and towing method. TOWING METHODS 1. TRAILER - The vehicle is loaded onto and secured to a trailer and simply acts as "secured" cargo. 2. DOLLY - The vehicle is "partially" loaded and partially towed. Either front or rear wheels are loaded and secured to a "towing dolly" and the other wheels roll on the road. 3. TOW BAR - All of the vehicle wheels roll on the pavement. The towed vehicle's steering column must be unlocked so that it can track correctly behind the tow vehicle. WEIGHT RATINGS AND BRAKES ^ GVWR (Gross Vehicle Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle, passengers and cargo ^ GCWR (Gross Combined Weight Rating) - is the MAXIMUM allowable weight of the towing vehicle and the weight of the trailer or vehicle being towed, including all passengers and cargo ^ BRAKES - The motorhome brakes are designed and rated for the GVWR of that vehicle and will provide adequate braking for trailers and towing vehicles up to 680 kg (1500 lb) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 6022 CAUTION: SEPARATE AUXILIARY BRAKES ARE REQUIRED ON TRAILERS OR TOWED VEHICLES OVER 680 KG (1500 LBS). DO NOT CONNECT A TRAILER'S, DOLLY'S OR OTHER TOWED VEHICLE'S BRAKE SYSTEM TO THE TOWING VEHICLE'S BRAKE SYSTEM. TOWED VEHICLES 1. Trailer-towed - The vehicle should be loaded on the trailer in a manner to: a. achieve a trailer tongue load of 10-15% of total trailer weight, b. not exceed the trailer or hitch ratings and c. be securely tied down. 2. Dolly-towed - For front wheel drive vehicles, towing an automatic transaxle (ATX)-equipped vehicle behind another vehicle, such as a Recreational Vehicle (RV), requires that a front wheel dolly or trailer be used. NOTE: TEMPO ALL-WHEEL DRIVE MODELS MUST BE TRAILER-TOWED. DO NOT TOW THESE VEHICLES USING A TWO-WHEEL TOWING DOLLY. CAUTION: DO NOT TOW A VEHICLE WITH AN AUTOMATIC (ATX) TRANSAXLE WITH THE DRIVE WHEELS ON THE GROUND. DAMAGE TO THE TRANSAXLE MAY RESULT. 3. Tow Bar-towed - Vehicles which can be successfully towed with a tow bar are listed in the following chart. Additional vehicle-specific information follows the chart. ALL VEHICLES NOTE: DO NOT TOW ANY VEHICLE AT A SPEED FASTER THAN 88 KM/H (55 MPH). THE MAXIMUM TOWING DISTANCE (WHEN TOWED CORRECTLY) IS UNLIMITED. WARNING: NEVER USE A TOW BAR THAT ATTACHES ONLY TO THE BUMPER. MTX-EQUIPPED VEHICLES Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Behind RVs Guidelines > Page 6023 Towing a manual transaxle (MTX)-equipped vehicle with the drive wheels on the ground is acceptable only if the vehicle is towed in a forward direction. The parking brake must be released and the gear shift lever must be in Neutral. ^ For Aspire, Festiva, Escort and Tracer, the ignition key must be in the ACO position, the battery must be disconnected to eliminate battery drain, and the steering wheel must be unlocked ^ For Capri, the ignition key must be in the OFF position and the steering wheel unlocked ^ Refer to the specific vehicle Owner Guide for complete details CAUTION: TOWING MTX-EQUIPPED VEHICLES INCORRECTLY MAY RESULT IN TRANSAXLE DAMAGE. TRUCKS ^ The steering wheel must be unlocked by placing the ignition key in the OFF position ^ Manual transmission shift lever must be in Neutral ^ On 4X4 manual shift transfer cases, the shift lever must be in Neutral ^ 4X4 locking hubs (both manual and automatic) must be unlocked ^ Refer to the specific vehicle Owner Guide for complete details OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-24-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 504000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6028 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6029 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6030 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6031 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6032 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6033 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6034 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6035 Trailer Connector: Electrical Diagrams All Except Limited Edition and Electronic Group Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6036 Trailer/Camper Adapter For Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6037 Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6038 Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6043 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6044 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6045 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6046 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6047 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6048 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6049 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6050 Trailer Connector: Electrical Diagrams All Except Limited Edition and Electronic Group Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6051 Trailer/Camper Adapter For Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6052 Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 6053 Trailer/Camper Adapter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Technical Service Bulletins > Running Boards - Noise/Vibration Installation Tips Auxiliary Step / Running Board: Technical Service Bulletins Running Boards - Noise/Vibration Installation Tips Article No. 95-8-6 04/24/95 ^ RUNNING BOARDS - INCORRECTLY INSTALLED - NVH CONCERNS ^ NOISE - VIBRATION - RUNNING BOARDS - INCORRECTLY INSTALLED LIGHT TRUCK: 1987-90 BRONCO II 1987-95 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-95 F SUPER DUTY 1991-95 EXPLORER This TSB is being republished in its entirety to include vehicles through the 1995 model year. ISSUE: Running boards which are incorrectly installed may result in noise/vibration complaints. ACTION: Install running boards to either the body or frame; NEVER to both unless the mounting system uses isolated mounts. A manufacturer's instruction to attach running boards to both body and frame should be immediately questioned because such action provides a direct path from chassis to body for road vibration and noise. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-4-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 108000, 702000, 703000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Interior Handle: > 94229 > Oct > 94 > Inside Door Handle - Breaks Front Door Interior Handle: Customer Interest Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off Front Door Interior Handle: Customer Interest Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6075 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6076 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 94229 > Oct > 94 > Inside Door Handle - Breaks Front Door Interior Handle: All Technical Service Bulletins Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off Front Door Interior Handle: All Technical Service Bulletins Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6086 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6087 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6088 Front Door Interior Handle: By Symptom Technical Service Bulletin # 94712 Date: 940406 Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6089 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6090 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Technical Service Bulletin # 94229 Date: 941031 Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6091 ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Technical Service Bulletin # 94712 Date: 940406 Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6092 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6093 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6094 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Technical Service Bulletin # 94229 Date: 941031 Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 6095 ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series Front Door Panel: Service and Repair Base Series Removal Front Door Base Series Four Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series > Page 6100 Front Door Base Series Two Door 1. Remove the two screws retaining the door trim panel located above the door handle. Also remove one screw in the upper front portion of door trim panel. 2. Remove trim cup at the door handle using a screwdriver or sharp object. Retention nibs will flex for easy removal. 3. At each plastic clip location, pry the door inner panel using the door trim panel removing tool from Rotunda Moulding/Trim Kit 107-00401 or equivalent. 4. When wiring and disengagement of trim clips is completed, it is recommended that to remove panel, lift slightly to remove flange at the top of door trim panel from trough in the glass weatherstrip. Pay special attention to the cut-out in the door trim panel for the door handle, so that it clears the handle during removal without breakage. NOTE: Do not pull on the trim panel to remove clips from the inner panel holes. Installation 1. Replace any bent, damaged, or missing plastic clips on the door trim panel to the door inner panel, firmly loading clips into slots provided on door trim panel. 2. Hold door trim panel while installing socket and bulb to illuminated courtesy lamp. 3. Load door trim panel to door assembly by first loading flange at top of door trim panel into trough in door glass weatherstrip. Align plastic clips to holes in door inner panel and tap panel slightly to engage clips. NOTE: Be cautious while loading panel over door handle. 4. Connect the power window and door lock control switch to the connector on the wire harness. Reinstall two screws and snap connector on harness to power mirror control switch. 5. Reinstall power control switch plate into the opening provided, loading control switch at front edge first. Then, feeding clip in slot at rear edge, Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series > Page 6101 apply pressure to engage clip. 6. Reinstall trim cup at door handle, applying pressure to snap retention nibs into door trim panel. 7. Reinstall two screws retaining door trim panel located above the door handle. Also reinstall one screw in the upper front portion of door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series > Page 6102 Front Door Panel: Service and Repair Hi-Series Hi-Series Removal Front Door Hi Series Four Door Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series > Page 6103 Front Door Hi Series Two Door 1. Remove the two screws retaining the door trim panel located above the door handle. Also remove one screw in the upper front portion of door trim panel. 2. Remove trim cut at the door handle using a screwdriver or sharp object. Retention nibs will flex for easy removal. 3. To remove power window door lock and mirror control plate, use notch located at lower end of plate using a screwdriver to lift and remove. 4. Remove plate from door trim panel pulling wire harness from inside of panel. 5. From bottom of plate, remove two screws and disconnect connector from switches; then flex finger on power mirror switch connector to disconnect. 6. At each plastic clip location, pry the door trim panel away from the door inner panel using the door trim panel removing tool from Rotunda Moulding Trim Kit 107-00401 or equivalent. 7. When wiring and disengagement of trim clips is completed, it is recommended that to remove panel, lift slightly to remove flange at the top of door trim panel from trough in the glass weatherstrip. Pay special attention to the cut-out in the door trim panel for the door handle, so that it clears the handle during removal without breakage. NOTE: Do not pull on the trim panel to remove clips from the inner panel holes. 8. Disconnect socket and bulb from illuminated courtesy lamp before total removal of panel. Installation Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Base Series > Page 6104 1. Replace any bent, damaged or missing plastic clips on the door trim panel to the door inner panel, firmly loading clips into slots provided on door trim panel. 2. Hold door trim panel while installing socket and bulb to illuminated courtesy lamp. 3. Load door trim panel to door assembly by first loading flange at top of door trim panel into trough in door glass weatherstrip. Align plastic clips to holes in door inner panel and top panel slightly to engage clips. NOTE: Be cautious while loading panel over door handle. 4. Connect the power window and door lock control switch to the connector on the wire harness. Reinstall two screws and snap connector on harness to power mirror control switch. 5. Reinstall power control switch plate into the opening provided, loading control switch at front edge first. Then, feeding clip in slot at rear edge, apply pressure to engage clip. 6. Reinstall trim cup at door handle applying pressure to snap retention nibs into door trim panel. 7. Reinstall two screws retaining door trim panel located above the door handle. Also reinstall one screw in the upper front portion of door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 94229 > Oct > 94 > Inside Door Handle - Breaks Rear Door Interior Handle: Customer Interest Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off Rear Door Interior Handle: Customer Interest Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6119 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6120 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 94229 > Oct > 94 > Inside Door Handle - Breaks Rear Door Interior Handle: All Technical Service Bulletins Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off Rear Door Interior Handle: All Technical Service Bulletins Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6130 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > 94712 > Apr > 94 > Door Panel Pull Handles - Paint Wears Off > Page 6131 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6132 Rear Door Interior Handle: By Symptom Technical Service Bulletin # 94712 Date: 940406 Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6133 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6134 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Technical Service Bulletin # 94229 Date: 941031 Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6135 ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Technical Service Bulletin # 94712 Date: 940406 Door Panel Pull Handles - Paint Wears Off Article No. 94-7-12 PAINT - WEARS OFF INSIDE DOOR TRIM PANEL PULL HANDLES LIGHT TRUCK: 1993-94 EXPLORER This article is being republished in its entirety to correct the dealer coding basic part number. ISSUE: The paint may wear off the inside door trim panel pull handles. This occurs because the paint does not adhere properly to plastic on the high wear surface. ACTION: Remove the existing paint worn pull handle and replace it with a color impregnated handle. Refer to the following procedure for service details. PROCEDURE FOR FRONT DOOR 2 AND 4 DOOR MODELS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6136 3. Measure from the inner sill on panel outward 1-13/16" (46 mm), Figure 1. 4. Measure from bottom of sill up 3/16" (4.76 mm). 5. With a 1/2" (12.7 mm) center aligned Blair cutter (Matco S3K 1/2 cutter, Matco C217X Arbor) cut a hole for access to pull handle retaining screw. See Figure 1. NOTE: TO ENSURE ADEQUATE CLEARANCE FOR SCREW REMOVAL, TILT THE CUTTER AT A SLIGHT DOWNWARD ANGLE AND MAINTAIN THE 3/16" (4.76 mm) DIMENSION FOR CENTER OF HOLE. 6. Remove screw to pull handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6137 7. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 8. Remove pull handle. 9. Install new pull handle. 10. Replace screw to pull handle. 11. Reinstall arm rest pad. 12. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6138 PROCEDURE FOR REAR DOORS 1. Remove the inner door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the removal procedure. 2. Remove the door arm rest panel (Phillip screws # 2). 3. Remove screw to pull handle. 4. Using a trim pad removal tool (Snap-on A16B or Matco UT3M) gently push between trim panel and end of pull handle and release lock tabs, Figure 2. 5. Remove pull handle. 6. Install new pull handle. 7. Replace screw to pull handle. 8. Reinstall arm rest pad. 9. Reinstall the door trim panel. Refer to the 1994 Explorer Service Manual, Section 01-05B, for the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-5-9 WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 940712ABT Replace Both Rear Door 0.6 Hr. Pull Handles 940712AB Replace One Rear Door 0.4 Hr. Pull Handle 940712AFT Replace Both Front Door 1.0 Hr. Pull Handles 940712AF Replace One Front Door 0.6 Hr. Pull Handle 940712AT Replace Front And Rear 1.5 Hrs. Door Pull Handles DEALER CODING BASIC PART NO. CONDITION CODE 7022666 D5 OASIS CODES: 107000, 112000 Technical Service Bulletin # 94229 Date: 941031 Inside Door Handle - Breaks Article No. 94-22-9 10/31/94 DOOR HANDLE - INSIDE - BREAKS WHEN OPENING DOOR LIGHT TRUCK: 1991-94 EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Interior Handle: > Page 6139 ISSUE: On some vehicles, the inside door handles may break off under abusive load conditions (e.g., childproof locks may be activated and rear seat occupants may pull with excessive force to try to open door). ACTION: Replace the broken inside door handies with new, stronger door handles to reduce fracture of the door handles. Refer to the following service procedure. SERVICE PROCEDURE To replace the inside door handle, refer to the REMOTE CONTROL ASSEMBLY removal and installation procedures of the Explorer Service Manual. Specific pages are as follows: 1991 01-14-32. 1992 01-14-35, 1993 01-14A-39, 1994 01-14A-27. NOTE: REPLACE ONLY THE BROKEN DOOR HANDLES. PART NUMBER PART NAME CLASS F4TZ-7821818-A Door Release Handle (R.H.) A F4TZ-7821819-A Door Release Handle (L.H.) A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Model Years And Basic Warranty Coverage For 1991 Model Year OPERATION DESCRIPTION TIME 942209AT Replace Both Inside Door 0.8 Hr. Handles 942209A Replace One Inside Door 0.5 Hr. Handle DEALER CODING BASIC PART NO. CONDITION CODE 7021818 01 OASIS CODES: 112000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Base Series Rear Door Panel: Service and Repair Base Series Rear Door, Base Removal 1. Remove the two screws retaining the door trim panel located above the door handle. Also remove one screw in the upper front portion of door trim panel. 2. Remove trim cup at the door handle using a screwdriver or sharp object. Retention nibs will flex for easy removal. 3. At each plastic clip location, pry the door trim panel away from the door inner panel using the door trim panel removing tool from Rotunda Moulding/Trim Kit 107-000401 or equivalent. 4. When wiring and disengagement of trim clips is completed, it is recommended that to remove panel, lift slightly to remove flange at the top of door trim panel from trough in the glass weatherstrip. Pay special attention to the cut-out in the door trim panel for the door handle so that it clears the handle during removal without breakage. NOTE: Do not pull on the trim panel to remove clips from the inner panel holes. Installation 1. Replace any bent, damaged or missing plastic clips on the door trim panel to the door inner panel, firmly loading clips into slots provided on door trim panel. 2. Load door trim panel to door assembly by first loading flange at top of door trim panel into trough in door glass weatherstrip. Align plastic clips to holes in door inner panel and tap panel slightly to engage clips. NOTE: Be cautious while loading panel over door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Base Series > Page 6144 3. Reinstall trim cup at door handle, applying pressure to snap retention nibs into door trim panel. 4. Reinstall two screws retaining door trim panel located above the door handle. Also reinstall one screw in the upper front portion of door trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Base Series > Page 6145 Rear Door Panel: Service and Repair Hi-Series Removal 1. Remove the two screws retaining the door trim panel located above the door handle. 2. Remove trim cup at the door handle using a screwdriver or sharp object. Retention nibs will flex for easy removal. 3. To remove power window control plate, use notch located at lower end of plate using a screwdriver to lift and remove. 4. Remove plate from door trim panel pulling wire harness from inside of panel. 5. From bottom of plate, remove two screws and disconnect connector from switch. 6. At each plastic clip location, pry the door trim panel away from the door inner panel using the door trim panel removing tool from Rotunda Moulding/Trim Kit 107-00401 or equivalent. 7. When wiring and disengagement of trim clips is completed, it is recommended that to remove panel, lift slightly to remove flange at the top of door trim panel from trough in the glass weatherstrip. Installation 1. Replace any bent, damaged or missing plastic clips on the door trim panel to the door inner panel, firmly loading clips into slots provided on door trim panel. 2. Load door trim panel to door assembly by first loading flange at top of door trim panel into trough in door glass weatherstrip. Align plastic clips to holes in door inner panel and tap panel slightly to engage clips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Base Series > Page 6146 NOTE: Be cautious while loading panel over door handle. 3. Connect the power window switch to the connector on the wire harness. Reinstall two screws and snap connector on harness. 4. Reinstall power control switch plate into opening provided, loading control switch at front edge first. Then feeding clip in slot at rear edge, apply pressure to engage clip. 5. Reinstall trim cup at door handle applying pressure to snap retention nibs into door trim panel. 6. Reinstall two screws retaining door trim panel located above door handle. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 6153 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement Technical Service Bulletin # 99S34 Date: 000101 Recall - Liftgate Bracket Reinforcement 99334 SAFETY RECALL Certain 1993 through 1995 Model Year Explorers-Liftgate Bracket Reinforcement ^ Original - January, 2000 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Supplement # 1 - April 4, 2000 ^ Dealer Letter ^ Attachment III ^ Liftgate Bracket Reinforcement - IMPORTANT INFORMATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6163 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6164 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII Manual for Refund information. RENTAL CARS Rentals are not approved for this program. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6165 LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6166 PARTS ORDERING INFORMATION Parts will not be direct shipped for this recall Order your parts requirement through normal order processing channels as noted below: Structural Adhesive Ordering Information Structural adhesive is only required when performing Service Procedure B (Cracked or torn liftgates.) The following metal or panel bonding adhesives, or equivalent must be used. Lord Corporation: ^ FUSOR 109B Metal Bonding Adhesive - 50 ML (1.7 oz) cartridge - uses applicator gun from Safety Recall 97S88. Contains enough adhesive to do about four (4) vehicles. (Conversion kit 513 for standard caulking gun is also available). or ^ FUSOR 108B Metal Bonding Adhesive - 300 ML (10.1 oz) cartridge - uses applicator gun 301 available from your local distributor. ^ Obtain locally. Call 1-800-234-FUSOR ext. 3 to find nearest local distributor. 3M Automotive Aftermarket Division: ^ Panel Bonding Adhesive # 08115 - 200ML (approx 6 oz) cartridge ^ One cartridge contains enough adhesive to do about 12 vehicles ^ Obtain from your local 3M distributors. If you need further assistance call 1-800-521-8180 ext. 5165 REPLACEMENT LIFTGATES AND FCS-700 TAGS Replacements: The liftgate is only replaced if the sheet metal at the attachment area is cracked or torn beyond the perimeter of the 7-rivet reinforcement plate. However, you must call the Recall Hotline at 1-800-325-5621 for prior approval. NOTE: Do not install Reinforcement Plate Kit on replacement liftgate. FCS-700 Tags: To avoid a "charge-back" for the replacement of the liftgate, cut out the damaged section of the liftgate, attach the completed FCS-700 tag to the cut out piece and return it to Ford Motor Company. (Only return one side if both sides are cracked or torn beyond the perimeter of the 7-rivet reinforcement plate ). DEALER PRICE For latest prices, refer to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6167 ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Overview Information HYDRAULIC LIFT CYLINDER BRACKET REINFORCEMENT AFFECTED VEHICLES CERTAIN 1993-1995 EXPLORER OVERVIEW Some Explorers may develop cracks in the liftgate bracket attachment area. In some rare cases, the bracket may separate from the liftgate. The following service procedures are designed to strengthen the attachment of the lift cylinder to the liftgate: Service Procedure A: This is the normal procedure to reinforce liftgate attachments that are not cracked and is only used when the spot welds on BOTH bracket attachments are free from any cracks or damage. The repair involves installation of a narrow reinforcement plate and is attached with four (4) rivets. This reinforcement plate will be referred to as the 4-rivet plate. Service Procedure B: This service procedure is designed to repair and strengthen liftgate brackets that have cracked metal around the liftgate bracket spot welds or brackets that have separated from the liftgate. The repair involves installation of a wide reinforcement plate and is attached with seven (7) rivets and structural adhesive. This plate will be referred to as the 7-rivet plate. Call the recall hotline at 1-800-325-5621 if the liftgate crack or torn sheet metal extends beyond the perimeter of the 7-rivet plate. THE FOLLOWING CAUTIONS APPLY TO ALL SERVICE PROCEDURES: A. BE SURE TO USE THE CORRECT REINFORCEMENT PLATE ON EACH SIDE OF THE VEHICLE. PLATES ARE MARKED "R" OR "L". B. MARK AND DRILL HOLES ONLY IN THE ORDER DESCRIBED TO ENSURE ACCURATE POSITIONING OF THE PLATE. Service Procedure A This is the normal procedure to reinforce liftgate attachments that are not cracked and is only used when the spot welds on BOTH bracket attachments are free from any cracks or damage. The repair involves installation of a narrow reinforcement plate and is attached with four (4) rivets. This reinforcement plate will be referred to as the 4-rivet plate. 1. Open the liftgate and position a protective cover over the cargo area. 2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Disconnect the lift cylinders from the upper lift cylinder brackets. keep the lift cylinders connected to the lower lift cylinder brackets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6168 4. Following the sheet metal contours, position the 4-rivet plate over the upper lift cylinder bracket. See Figure 1. If the lift cylinder bracket welds extend above the bracket surface, grind the welds flush with the bracket surface. 5. Using the 4-rivet plate as a guide, center punch the location for rivet # 1. See Figure 1. This rivet location cannot be on an existing weld. NOTE: IF VARIATIONS EXIST BETWEEN THE 4-RIVET PLATE AND THE LIFTGATE SURFACE, MODIFY THE PLATE TO CONFORM TO THE LIFTGATE INNER PANEL SURFACE WITH-OUT SCRATCHING OR BREAKING THE PAINT. CAUTION: Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel. 6. Drill a 5 mm (3/16-inch) hole for rivet # 1. Apply Super Seal Anticorrosion Compound (F3AZ-19515-SA) or equivalent to the hole to protect the bare metal from corrosion. 7. Position the 4-rivet plate and install rivet # 1. Make sure the plate fits tightly against the liftgate. 8. Using the 4-rivet plate as a guide, center punch the location for rivet # 2. See Figure 1. 9. Drill a 5 mm (3/16-inch) hole for rivet # 2. Apply Super Seal to the hole, then install rivet # 2. 10. Using the 4-rivet plate as a guide, center punch the locations for rivets # 3 and # 4. 11. Drill 5 mm (3/16-inch) holes for rivets # 3 and # 4. Apply Super Seal to the holes, then install rivets # 3 and # 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6169 12. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 2. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally. 13. Drill a 5 mm (3/16-inch) hole at the center-punched location. Apply Super Seal to the hole, and install a rivet. 14. Repeat Steps 4 through 13 for the opposite side of the vehicle. 15. Connect the lift cylinders to the upper lift cylinder brackets. 16. Remove the jack stand. 17. Clean any excess Super Seal and metal shavings from the affected areas. 18. Verify liftgate operation. Service Procedure B This service procedure is designed to repair and strengthen liftgate brackets that have cracked metal around the liftgate bracket spot welds or brackets that have separated from the liftgate. The repair involves installation of a wide reinforcement plate and is attached with seven (7) rivets and structural adhesive. This plate will be referred to as the 7-rivet plate. 1. Open the liftgate and position a protective cover over the cargo area. 2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Disconnect the lift cylinders from the upper lift cylinder brackets. Keep the lift cylinders connected to the lower lift cylinder brackets. 4. If the lift cylinder is separated from the liftgate: a. Straighten out the separated lift cylinder bracket. b. Position the bracket into its original position. It must have a close fit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6170 5. Position the 7-rivet plate over the lift cylinder bracket in the location shown in Figure 3. If the sheet metal crack or tear-out is covered by the 7-rivet plate, proceed to Step 3. See Figure 4. If the sheet metal crack or tear-out goes beyond the 7-rivet plate, the liftgate must be replaced. Liftgate replacement requires prior approval. Also, the damaged section must be cut out of the liftgate and returned to Ford Motor Company with the FCS 700 tag. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6171 6. With the 7-rivet plate correctly positioned over the lift cylinder bracket, center punch the two (2) rivet hole locations shown in Figure 5. This step marks the lift cylinder bracket rivet locations. 7. Remove the 7-rivet plate and, if separated, the lift cylinder bracket. Proceed to Step 12 if not separated. 8. Using a 5 mm (3/16-inch) drill, drill two holes in the marked locations in the lift cylinder bracket. 9. Position the lift cylinder bracket back onto the liftgate. 10. Using the lift cylinder bracket as a guide, center punch two rivet hole locations in the liftgate. 11. Remove the lift cylinder bracket. CAUTION: Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel. 12. Drill two (2) 5 mm (3/16-inch) holes: a. If not separated - in the lift cylinder brackets and into the liftgate. b. If separated - in the liftgate only. 13. Obtain one cartridge of Lord FUSOR 109B or 3M # 08115 Panel Bonding Adhesive, or equivalent. Then, dispense approximately a one-inch ribbon of adhesive on a piece of paper and discard. This only needs to be done the first time the adhesive cartridge is used. 14. Dispense approximately one (1) teaspoon of adhesive on a suitable non-porous mixing surface. Mix the adhesive thoroughly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6172 15. Spread the adhesive on the 7-rivet plate as shown in Figure 6. 16. Install two (2) rivets in the locations shown in Figure 6. Proceed to Step 20 if not separated. 17. Install the lift cylinder bracket over the rivets and onto the 7-rivet plate. See Figure 6. Make sure the lift cylinder bracket is in the proper orientation. 18. Spread the adhesive on the lift cylinder bracket. See Figure 6. 19. Install the lift cylinder bracket, 7-rivet plate and the rivets as an assembly onto the liftgate. Proceed to Step 21. 20. Install the 7-rivet plate and the rivets as an assembly onto the liftgate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6173 21. Secure the two rivets. See Figure 7. 22. Center punch the five (5) remaining rivet locations. See Figure 7. 23. Drill 5 mm (3/16-inch) holes in the five rivet locations. 24. Following the numbered sequence shown in Figure 8, install the remaining five (5) rivets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6174 25. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 9. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally. 26. Drill a 5 mm (3/16-inch) hole at the center-punched location. Install a rivet. 27. Repeat this procedure for opposite side lift cylinder bracket. 28. Connect the lift cylinders to the upper lift cylinder brackets. 29. Remove the jack stand. 30. Verify liftgate operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6175 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6176 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6177 Supplement # 1 - Attachment III - Important Information EXPLORER LIFTGATE WITH TORN SHEETMETAL Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6178 If the 7-rivet plate completely covers the torn sheetmetal area: ^ The liftgate does not require replacement. ^ Follow Repair Procedure B of Attachment III for Safety Recall 99S34. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage Technical Service Bulletin # 95M87 Date: 951001 Campaign - Liftgate Bracket Extended Coverage 95M87 OWNER NOTIFICATION PROGRAM Certain 1991-1995 Explorers - Liftgate Bracket - Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6183 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6184 Attachment I - Administrative Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Owner Refunds See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the selling dealer), enter using DWE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6185 Program Code Field - 95M87 Misc. Expense Field - REFUND Misc. Expense Field - ADMIN Misc. Expense Field - 0.2 Hr. Attachment II - Labor and Parts Information Affected Vehicles Certain 1991-1995 Model year Explorer Reinforcement Liftgate Brackets Labor Allowances Submit using DWE. Parts Requirements Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: Order Processing Center DOES II Updated Price Book Claims Preparation Enter using DWE. Use code information shown below: Program Code - 95M87 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6186 Explorer Liftgate Enhancement Bracket Installation Installation 1. Open liftgate and position a protective cover over cargo area. 2. Support liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Using a small screwdriver, pry the locking springs out of the ball sockets of the hydraulic lift cylinders at the liftgate only. Keep hydraulic lift cylinders connected to the body. CAUTION: BE SURE TO USE THE CORRECT ENHANCEMENT BRACKET ON EACH SIDE OF THE VEHICLE. BRACKETS ARE MARKED "R" OR "L". CAUTION: MARK AND DRILL HOLES ONLY IN ORDER GIVEN TO ENSURE ACCURATE POSITIONING OF BRACKET. NOTE: If the fusion weld extends above the surface of the bracket, grind the fusion weld flush with the surface of the bracket. 4. Position enhancement bracket over existing lift bracket following body contours and mark location of hole indicated for rivet # 1 in Figure 1. DO NOT drill into the existing welds. Center punch the location. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6187 If variation exists between the enhancement bracket and liftgate surface, then modify bracket to conform to liftgate inner panel surface without scratching or breaking paint. CAUTION: APPLY TAPE TO A 3/16" DRILL BIT TO CREATE A "DRILL STOP" NO MORE THAN ONE-HALF INCH (1/2") FROM THE TIP TO PREVENT DRILLING THROUGH LIFTGATE OUTER PANEL. 5. Drill first 3/16" hole at marked location. Apply Super Seal Anticorrosion Compound (Part No. F3AZ-1 951 5-SA) or equivalent to the hole to protect bare metal against corrosion. 6. Position enhancement bracket and install one supplied pop rivet ensuring bracket is snugged up tightly against liftgate. 7. With enhancement bracket properly aligned with body contours, center punch hole as indicated for rivet # 2 in figure 1. 8. Drill second 3/16" hole, apply Super Seal then install pop rivet as instructed in step 5 and 6. 9. Drill remaining two holes using holes in enhancement bracket as a guide. Apply Super Seal and install pop rivets as instructed in previous steps. CAUTION: APPLY A PIECE OF MASKING TAPE TO THE AFFECTED AREA OF LOWER BRACKET TO PREVENT ANY PAINT DAMAGE FROM OCCURRING WHILE DRILLING. 10. Locate and mark the center point between the two upper spot welds on the lower bracket. This point should be approximately 20 mm from the top of the bracket and centered horizontally. 11. Center punch then drill a 3/16" hole, apply Super Seal then install a pop rivet as instructed in previous steps. See Figure 2. 12. Repeat Steps 4 through 11 for opposite side of vehicle. 13. Install ball sockets of hydraulic lift cylinders on ball studs on bracket. Push lift cylinders at ball socket until assembly snaps into place. Verify locking spring clip is properly positioned. 14. Remove jack stand. 15. Clean any excess Super Seal and metal shavings from affected areas. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6188 16. Verify Liftgate operation. Inspection Procedures In some isolated cases, the Liftgate may be damaged in the area around the bracket which connects the hydraulic lift cylinder to the liftgate. If damaged, the following questions are to be answered: If the answer to any of these questions is "yes", then the liftgate must be replaced. If the answer to all of these questions is "no", then install the bracket reinforcement kit and release the vehicle. NOTE: If the liftgate is replaced, do not install the reinforcement kits. NOTE: After painting a replacement liftgate, the existing components (wiper motor, rear window, electrical harness, etc.) are to be transferred to the new Liftgate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6189 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > Recalls for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6190 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement Technical Service Bulletin # 99S34 Date: 000101 Recall - Liftgate Bracket Reinforcement 99334 SAFETY RECALL Certain 1993 through 1995 Model Year Explorers-Liftgate Bracket Reinforcement ^ Original - January, 2000 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter ^ Supplement # 1 - April 4, 2000 ^ Dealer Letter ^ Attachment III ^ Liftgate Bracket Reinforcement - IMPORTANT INFORMATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6196 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6197 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE: Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct all affected vehicles on your dealer VIN list which you will receive in the Ford Dealer Consolidated Communicator (FDCC) or by FAX. Also, correct other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give the owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII Manual for claims preparation and submission information. OWNER REFUNDS Ford Motor will only refund owner-paid repairs made before the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the servicing dealer.) Refer to ACESII Manual for Refund information. RENTAL CARS Rentals are not approved for this program. Attachment II - Labor and Parts Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6198 LABOR ALLOWANCES Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6199 PARTS ORDERING INFORMATION Parts will not be direct shipped for this recall Order your parts requirement through normal order processing channels as noted below: Structural Adhesive Ordering Information Structural adhesive is only required when performing Service Procedure B (Cracked or torn liftgates.) The following metal or panel bonding adhesives, or equivalent must be used. Lord Corporation: ^ FUSOR 109B Metal Bonding Adhesive - 50 ML (1.7 oz) cartridge - uses applicator gun from Safety Recall 97S88. Contains enough adhesive to do about four (4) vehicles. (Conversion kit 513 for standard caulking gun is also available). or ^ FUSOR 108B Metal Bonding Adhesive - 300 ML (10.1 oz) cartridge - uses applicator gun 301 available from your local distributor. ^ Obtain locally. Call 1-800-234-FUSOR ext. 3 to find nearest local distributor. 3M Automotive Aftermarket Division: ^ Panel Bonding Adhesive # 08115 - 200ML (approx 6 oz) cartridge ^ One cartridge contains enough adhesive to do about 12 vehicles ^ Obtain from your local 3M distributors. If you need further assistance call 1-800-521-8180 ext. 5165 REPLACEMENT LIFTGATES AND FCS-700 TAGS Replacements: The liftgate is only replaced if the sheet metal at the attachment area is cracked or torn beyond the perimeter of the 7-rivet reinforcement plate. However, you must call the Recall Hotline at 1-800-325-5621 for prior approval. NOTE: Do not install Reinforcement Plate Kit on replacement liftgate. FCS-700 Tags: To avoid a "charge-back" for the replacement of the liftgate, cut out the damaged section of the liftgate, attach the completed FCS-700 tag to the cut out piece and return it to Ford Motor Company. (Only return one side if both sides are cracked or torn beyond the perimeter of the 7-rivet reinforcement plate ). DEALER PRICE For latest prices, refer to: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6200 ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Overview Information HYDRAULIC LIFT CYLINDER BRACKET REINFORCEMENT AFFECTED VEHICLES CERTAIN 1993-1995 EXPLORER OVERVIEW Some Explorers may develop cracks in the liftgate bracket attachment area. In some rare cases, the bracket may separate from the liftgate. The following service procedures are designed to strengthen the attachment of the lift cylinder to the liftgate: Service Procedure A: This is the normal procedure to reinforce liftgate attachments that are not cracked and is only used when the spot welds on BOTH bracket attachments are free from any cracks or damage. The repair involves installation of a narrow reinforcement plate and is attached with four (4) rivets. This reinforcement plate will be referred to as the 4-rivet plate. Service Procedure B: This service procedure is designed to repair and strengthen liftgate brackets that have cracked metal around the liftgate bracket spot welds or brackets that have separated from the liftgate. The repair involves installation of a wide reinforcement plate and is attached with seven (7) rivets and structural adhesive. This plate will be referred to as the 7-rivet plate. Call the recall hotline at 1-800-325-5621 if the liftgate crack or torn sheet metal extends beyond the perimeter of the 7-rivet plate. THE FOLLOWING CAUTIONS APPLY TO ALL SERVICE PROCEDURES: A. BE SURE TO USE THE CORRECT REINFORCEMENT PLATE ON EACH SIDE OF THE VEHICLE. PLATES ARE MARKED "R" OR "L". B. MARK AND DRILL HOLES ONLY IN THE ORDER DESCRIBED TO ENSURE ACCURATE POSITIONING OF THE PLATE. Service Procedure A This is the normal procedure to reinforce liftgate attachments that are not cracked and is only used when the spot welds on BOTH bracket attachments are free from any cracks or damage. The repair involves installation of a narrow reinforcement plate and is attached with four (4) rivets. This reinforcement plate will be referred to as the 4-rivet plate. 1. Open the liftgate and position a protective cover over the cargo area. 2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Disconnect the lift cylinders from the upper lift cylinder brackets. keep the lift cylinders connected to the lower lift cylinder brackets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6201 4. Following the sheet metal contours, position the 4-rivet plate over the upper lift cylinder bracket. See Figure 1. If the lift cylinder bracket welds extend above the bracket surface, grind the welds flush with the bracket surface. 5. Using the 4-rivet plate as a guide, center punch the location for rivet # 1. See Figure 1. This rivet location cannot be on an existing weld. NOTE: IF VARIATIONS EXIST BETWEEN THE 4-RIVET PLATE AND THE LIFTGATE SURFACE, MODIFY THE PLATE TO CONFORM TO THE LIFTGATE INNER PANEL SURFACE WITH-OUT SCRATCHING OR BREAKING THE PAINT. CAUTION: Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel. 6. Drill a 5 mm (3/16-inch) hole for rivet # 1. Apply Super Seal Anticorrosion Compound (F3AZ-19515-SA) or equivalent to the hole to protect the bare metal from corrosion. 7. Position the 4-rivet plate and install rivet # 1. Make sure the plate fits tightly against the liftgate. 8. Using the 4-rivet plate as a guide, center punch the location for rivet # 2. See Figure 1. 9. Drill a 5 mm (3/16-inch) hole for rivet # 2. Apply Super Seal to the hole, then install rivet # 2. 10. Using the 4-rivet plate as a guide, center punch the locations for rivets # 3 and # 4. 11. Drill 5 mm (3/16-inch) holes for rivets # 3 and # 4. Apply Super Seal to the holes, then install rivets # 3 and # 4. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6202 12. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 2. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally. 13. Drill a 5 mm (3/16-inch) hole at the center-punched location. Apply Super Seal to the hole, and install a rivet. 14. Repeat Steps 4 through 13 for the opposite side of the vehicle. 15. Connect the lift cylinders to the upper lift cylinder brackets. 16. Remove the jack stand. 17. Clean any excess Super Seal and metal shavings from the affected areas. 18. Verify liftgate operation. Service Procedure B This service procedure is designed to repair and strengthen liftgate brackets that have cracked metal around the liftgate bracket spot welds or brackets that have separated from the liftgate. The repair involves installation of a wide reinforcement plate and is attached with seven (7) rivets and structural adhesive. This plate will be referred to as the 7-rivet plate. 1. Open the liftgate and position a protective cover over the cargo area. 2. Support the liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Disconnect the lift cylinders from the upper lift cylinder brackets. Keep the lift cylinders connected to the lower lift cylinder brackets. 4. If the lift cylinder is separated from the liftgate: a. Straighten out the separated lift cylinder bracket. b. Position the bracket into its original position. It must have a close fit. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6203 5. Position the 7-rivet plate over the lift cylinder bracket in the location shown in Figure 3. If the sheet metal crack or tear-out is covered by the 7-rivet plate, proceed to Step 3. See Figure 4. If the sheet metal crack or tear-out goes beyond the 7-rivet plate, the liftgate must be replaced. Liftgate replacement requires prior approval. Also, the damaged section must be cut out of the liftgate and returned to Ford Motor Company with the FCS 700 tag. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6204 6. With the 7-rivet plate correctly positioned over the lift cylinder bracket, center punch the two (2) rivet hole locations shown in Figure 5. This step marks the lift cylinder bracket rivet locations. 7. Remove the 7-rivet plate and, if separated, the lift cylinder bracket. Proceed to Step 12 if not separated. 8. Using a 5 mm (3/16-inch) drill, drill two holes in the marked locations in the lift cylinder bracket. 9. Position the lift cylinder bracket back onto the liftgate. 10. Using the lift cylinder bracket as a guide, center punch two rivet hole locations in the liftgate. 11. Remove the lift cylinder bracket. CAUTION: Apply tape to a 5 mm (3/16-inch) drill bit to create a "drill stop" no more than one-half inch (1/2") from the tip of the drill. This will help prevent drilling through the liftgate outer panel. 12. Drill two (2) 5 mm (3/16-inch) holes: a. If not separated - in the lift cylinder brackets and into the liftgate. b. If separated - in the liftgate only. 13. Obtain one cartridge of Lord FUSOR 109B or 3M # 08115 Panel Bonding Adhesive, or equivalent. Then, dispense approximately a one-inch ribbon of adhesive on a piece of paper and discard. This only needs to be done the first time the adhesive cartridge is used. 14. Dispense approximately one (1) teaspoon of adhesive on a suitable non-porous mixing surface. Mix the adhesive thoroughly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6205 15. Spread the adhesive on the 7-rivet plate as shown in Figure 6. 16. Install two (2) rivets in the locations shown in Figure 6. Proceed to Step 20 if not separated. 17. Install the lift cylinder bracket over the rivets and onto the 7-rivet plate. See Figure 6. Make sure the lift cylinder bracket is in the proper orientation. 18. Spread the adhesive on the lift cylinder bracket. See Figure 6. 19. Install the lift cylinder bracket, 7-rivet plate and the rivets as an assembly onto the liftgate. Proceed to Step 21. 20. Install the 7-rivet plate and the rivets as an assembly onto the liftgate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6206 21. Secure the two rivets. See Figure 7. 22. Center punch the five (5) remaining rivet locations. See Figure 7. 23. Drill 5 mm (3/16-inch) holes in the five rivet locations. 24. Following the numbered sequence shown in Figure 8, install the remaining five (5) rivets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6207 25. Center punch the center point between the two upper spot welds on the lower lift cylinder bracket. See Figure 9. This point should be approximately 20 mm (3/4 inch) from the top of the bracket and centered horizontally. 26. Drill a 5 mm (3/16-inch) hole at the center-punched location. Install a rivet. 27. Repeat this procedure for opposite side lift cylinder bracket. 28. Connect the lift cylinders to the upper lift cylinder brackets. 29. Remove the jack stand. 30. Verify liftgate operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6208 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6209 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6210 Supplement # 1 - Attachment III - Important Information EXPLORER LIFTGATE WITH TORN SHEETMETAL Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 99S34 > Jan > 00 > Recall - Liftgate Bracket Reinforcement > Page 6211 If the 7-rivet plate completely covers the torn sheetmetal area: ^ The liftgate does not require replacement. ^ Follow Repair Procedure B of Attachment III for Safety Recall 99S34. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage Technical Service Bulletin # 95M87 Date: 951001 Campaign - Liftgate Bracket Extended Coverage 95M87 OWNER NOTIFICATION PROGRAM Certain 1991-1995 Explorers - Liftgate Bracket - Additional Coverage ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Refund Codes ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6216 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6217 Attachment I - Administrative Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Owner Refunds See ACESII Manual, Section 3-59 for submission procedures. For owner-paid repairs made before date of the Owner Letter (or after the date of the Owner Letter if an emergency repair was made away from the selling dealer), enter using DWE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6218 Program Code Field - 95M87 Misc. Expense Field - REFUND Misc. Expense Field - ADMIN Misc. Expense Field - 0.2 Hr. Attachment II - Labor and Parts Information Affected Vehicles Certain 1991-1995 Model year Explorer Reinforcement Liftgate Brackets Labor Allowances Submit using DWE. Parts Requirements Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: Order Processing Center DOES II Updated Price Book Claims Preparation Enter using DWE. Use code information shown below: Program Code - 95M87 Labor Operation - See Above See Sections 5 & 6 of the ACESII manual for detailed instructions. Attachment III - Technical Information Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6219 Explorer Liftgate Enhancement Bracket Installation Installation 1. Open liftgate and position a protective cover over cargo area. 2. Support liftgate with a tall jack stand covered with a cloth to protect the trim panel. 3. Using a small screwdriver, pry the locking springs out of the ball sockets of the hydraulic lift cylinders at the liftgate only. Keep hydraulic lift cylinders connected to the body. CAUTION: BE SURE TO USE THE CORRECT ENHANCEMENT BRACKET ON EACH SIDE OF THE VEHICLE. BRACKETS ARE MARKED "R" OR "L". CAUTION: MARK AND DRILL HOLES ONLY IN ORDER GIVEN TO ENSURE ACCURATE POSITIONING OF BRACKET. NOTE: If the fusion weld extends above the surface of the bracket, grind the fusion weld flush with the surface of the bracket. 4. Position enhancement bracket over existing lift bracket following body contours and mark location of hole indicated for rivet # 1 in Figure 1. DO NOT drill into the existing welds. Center punch the location. NOTE: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6220 If variation exists between the enhancement bracket and liftgate surface, then modify bracket to conform to liftgate inner panel surface without scratching or breaking paint. CAUTION: APPLY TAPE TO A 3/16" DRILL BIT TO CREATE A "DRILL STOP" NO MORE THAN ONE-HALF INCH (1/2") FROM THE TIP TO PREVENT DRILLING THROUGH LIFTGATE OUTER PANEL. 5. Drill first 3/16" hole at marked location. Apply Super Seal Anticorrosion Compound (Part No. F3AZ-1 951 5-SA) or equivalent to the hole to protect bare metal against corrosion. 6. Position enhancement bracket and install one supplied pop rivet ensuring bracket is snugged up tightly against liftgate. 7. With enhancement bracket properly aligned with body contours, center punch hole as indicated for rivet # 2 in figure 1. 8. Drill second 3/16" hole, apply Super Seal then install pop rivet as instructed in step 5 and 6. 9. Drill remaining two holes using holes in enhancement bracket as a guide. Apply Super Seal and install pop rivets as instructed in previous steps. CAUTION: APPLY A PIECE OF MASKING TAPE TO THE AFFECTED AREA OF LOWER BRACKET TO PREVENT ANY PAINT DAMAGE FROM OCCURRING WHILE DRILLING. 10. Locate and mark the center point between the two upper spot welds on the lower bracket. This point should be approximately 20 mm from the top of the bracket and centered horizontally. 11. Center punch then drill a 3/16" hole, apply Super Seal then install a pop rivet as instructed in previous steps. See Figure 2. 12. Repeat Steps 4 through 11 for opposite side of vehicle. 13. Install ball sockets of hydraulic lift cylinders on ball studs on bracket. Push lift cylinders at ball socket until assembly snaps into place. Verify locking spring clip is properly positioned. 14. Remove jack stand. 15. Clean any excess Super Seal and metal shavings from affected areas. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6221 16. Verify Liftgate operation. Inspection Procedures In some isolated cases, the Liftgate may be damaged in the area around the bracket which connects the hydraulic lift cylinder to the liftgate. If damaged, the following questions are to be answered: If the answer to any of these questions is "yes", then the liftgate must be replaced. If the answer to all of these questions is "no", then install the bracket reinforcement kit and release the vehicle. NOTE: If the liftgate is replaced, do not install the reinforcement kits. NOTE: After painting a replacement liftgate, the existing components (wiper motor, rear window, electrical harness, etc.) are to be transferred to the new Liftgate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6222 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Shock / Support: > 95M87 > Oct > 95 > Campaign - Liftgate Bracket Extended Coverage > Page 6223 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip Frame: Technical Service Bulletins Frame - Rivet Replacement with Bolts Service Tip Article No. 97-4-7 02/17/97 FRAME - RIVET REPLACEMENT WITH BOLTS - SERVICE TIPS LIGHT TRUCK: 1980-96 BRONCO 1980-97 ECONOLINE, F-150-350 SERIES 1983-97 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F SUPER DUTY, F-47 1991-97 EXPLORER This TSB article is being republished in its entirety to include 1997 model year vehicles. ISSUE: Damaged or loose frame rivets should be replaced with approved service bolts. WELDING IS NOT ACCEPTABLE. ACTION: If service is required, replace standard rivets with approved service bolts. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: THE "HUCK" RIVET BETWEEN THE # 1 CROSSMEMBER AND THE LH FRAME RAIL SHOULD BE SERVICED PER TSB 91-25-18. THIS PROCEDURE DOES NOT APPLY. 1. Inspect for a loose or damaged rivet. 2. Remove any damaged or loose rivets. a. Drill a 3.175 mm (1/8") hole through the rivet. b. Redrill the same hole through the shank of the rivet. ^ Use an 8.731 mm (11/32") drill for 3/8" and 10 mm rivets. ^ Use a 9.525 mm (3/8") drill for 11.113 mm (7/16") rivets. c. Remove the rivet head with an air chisel. d. Drive out the rivet with a punch and hammer. 3. Line ream the hole to the replacement bolt nominal size with a hole tolerance of +/- 0.127 mm (0.005"). 4. Free hole of burrs after reaming to allow bolt head and nut to seat properly. 5. Select the bolt length to have a minimum of two (2) threads protruding from outer face of nut. Refer to the following Bolt Selection Chart for correct parts usage. NOTE: IF A FLANGE HEAD NUT AND BOLT ARE NOT AVAILABLE, GRADE 5 HEX HEADS MAY BE SUBSTITUTED WITH ONE (1) FLATWASHER REQUIRED UNDER THE NUT AND ONE (1) FLATWASHER REQUIRED UNDER THE BOLT HEAD. 6. Check to be sure there is a 12.7 mm (1/2") minimum clearance of bolt to adjacent components, except engine and transmission, which must have at least 19.05 mm (3/4") clearance to allow for powertrain roll. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Frame Rivet Replacement with Bolts Service Tip > Page 6228 7. Tighten the bolts to the specifications shown in the Bolt Selection Chart. NOTE: GRADE 8 BOLTS MAY BE SUBSTITUTED FOR ANY APPLICATION. Parts Block OTHER APPLICABLE ARTICLES: 96-4-11 SUPERSEDES: 96-15-11 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 970407A Replace Rivet 0.5 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 5005 57 OASIS CODES: 304000, 305000, 390000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles Arm Rest: Customer Interest Front Seat Center Armrest - Loose/Wobbles Article No. 94-24-10 11/28/94 FRONT SEAT CENTER ARMREST - LOOSE AND WOBBLES - VEHICLES WITH BUCKET SEATS AND FLOOR CONSOLE LIGHT TRUCK: 1989-90 BRONCO II 1989-94 RANGER 1991-94 EXPLORER ISSUE: The front seat center console may become loose and wobble from side to side. This may be caused by the console armrest mounting bracket becoming loose and/or weak under extreme load conditions. ACTION: Replace the center armrest console bracket with a new, more robust center armrest console bracket. Refer to the following for service details. SERVICE PROCEDURE REMOVAL 1. Verify the concern. NOTE: ALSO INSPECT THE ARMREST MOUNTING BRACKET WHICH RETAINS THE ARMREST TO THE CONSOLE. IF THE ARMREST BRACKET IS CONSTRUCTED OF PLASTIC, REFER TO TSB 93-23-19 FOR MORE DETAILS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6238 2. Remove the floor console assembly from the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6239 3. Remove the four (4) nuts retaining the old console armrest mounting bracket to the floor pan. Save the nuts and discard the bracket. Refer to Figure 2. INSTALLATION NOTE: BEFORE PROCEEDING, THE WELD STUDS MUST BE INSPECTED FOR DAMAGE (BENT, STRIPPED, SHEARED). IF ANY OF THESE CONDITIONS EXIST, THE WELD STUD(S) MUST BE REPLACED. REFER TO THE REPLACEMENT OF WELD STUD(S) SERVICE PROCEDURE LOCATED IN THIS ARTICLE BEFORE INSTALLING THE NEW BRACKET. 1. Position the armrest mounting bracket onto the weld studs and tighten nuts to 7-11 N-m (5-8 lb.ft.). Refer to Figure 2. 2. Install the floor console assembly into the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6240 3. Verify proper function of the armrest. 4. Following the instructions and precautions on the can, apply SuperSeal (F3AZ-19515-SA) to the affected area to ensure a proper seal. REPLACEMENT OF WELD STUD(S) 1. Use a grinding wheel or equivalent tool to remove damaged weld stud(s) from floor pan. 2. Use a punch and hammer to center punch location of damaged weld stud(s). 3. Drill 1/4 inch diameter hole(s) at center punch mark(s). 4. Insert repair bolt(s) (N606676-S36) and washer(s) through hole(s) and new console bracket from underside of vehicle. 5. Install repair nut(s) (N621905-S2) and torque to 9-11 N-m (6-8 lb.ft.). 6. Refer to the Installation Procedure in this TSB to complete the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: 93-23-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models And Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 942410A Replace Armrest Bracket 0.6 Hr. 942410B Additional Time To Replace 0.2 Hr. One Damaged Weld Stud 942410C Additional Time To Replace 0.3 Hr. Two Or Three Damaged Weld Studs 942410D Additional Time To Replace 0.4 Hr. All Four Damaged Studs DEALER CODING BASIC PART NO. CONDITION CODE 7045C52 01 OASIS CODES: 101000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles Arm Rest: All Technical Service Bulletins Front Seat Center Armrest - Loose/Wobbles Article No. 94-24-10 11/28/94 FRONT SEAT CENTER ARMREST - LOOSE AND WOBBLES - VEHICLES WITH BUCKET SEATS AND FLOOR CONSOLE LIGHT TRUCK: 1989-90 BRONCO II 1989-94 RANGER 1991-94 EXPLORER ISSUE: The front seat center console may become loose and wobble from side to side. This may be caused by the console armrest mounting bracket becoming loose and/or weak under extreme load conditions. ACTION: Replace the center armrest console bracket with a new, more robust center armrest console bracket. Refer to the following for service details. SERVICE PROCEDURE REMOVAL 1. Verify the concern. NOTE: ALSO INSPECT THE ARMREST MOUNTING BRACKET WHICH RETAINS THE ARMREST TO THE CONSOLE. IF THE ARMREST BRACKET IS CONSTRUCTED OF PLASTIC, REFER TO TSB 93-23-19 FOR MORE DETAILS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6246 2. Remove the floor console assembly from the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6247 3. Remove the four (4) nuts retaining the old console armrest mounting bracket to the floor pan. Save the nuts and discard the bracket. Refer to Figure 2. INSTALLATION NOTE: BEFORE PROCEEDING, THE WELD STUDS MUST BE INSPECTED FOR DAMAGE (BENT, STRIPPED, SHEARED). IF ANY OF THESE CONDITIONS EXIST, THE WELD STUD(S) MUST BE REPLACED. REFER TO THE REPLACEMENT OF WELD STUD(S) SERVICE PROCEDURE LOCATED IN THIS ARTICLE BEFORE INSTALLING THE NEW BRACKET. 1. Position the armrest mounting bracket onto the weld studs and tighten nuts to 7-11 N-m (5-8 lb.ft.). Refer to Figure 2. 2. Install the floor console assembly into the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6248 3. Verify proper function of the armrest. 4. Following the instructions and precautions on the can, apply SuperSeal (F3AZ-19515-SA) to the affected area to ensure a proper seal. REPLACEMENT OF WELD STUD(S) 1. Use a grinding wheel or equivalent tool to remove damaged weld stud(s) from floor pan. 2. Use a punch and hammer to center punch location of damaged weld stud(s). 3. Drill 1/4 inch diameter hole(s) at center punch mark(s). 4. Insert repair bolt(s) (N606676-S36) and washer(s) through hole(s) and new console bracket from underside of vehicle. 5. Install repair nut(s) (N621905-S2) and torque to 9-11 N-m (6-8 lb.ft.). 6. Refer to the Installation Procedure in this TSB to complete the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: 93-23-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models And Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 942410A Replace Armrest Bracket 0.6 Hr. 942410B Additional Time To Replace 0.2 Hr. One Damaged Weld Stud 942410C Additional Time To Replace 0.3 Hr. Two Or Three Damaged Weld Studs 942410D Additional Time To Replace 0.4 Hr. All Four Damaged Studs DEALER CODING BASIC PART NO. CONDITION CODE 7045C52 01 OASIS CODES: 101000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position Arm Rest: All Technical Service Bulletins Console Armrest - Squeaks In The Down Position Article No. 94-19-15 09/21/94 ^ CONSOLE ARMREST - SQUEAK IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST ^ NOISE - "SQUEAK" - FROM CONSOLE ARMREST IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may experience a "squeak" from the center console armrest when the armrest is down. This may be caused by a plastic spacer rubbing against the metal frame of the armrest. ACTION: Install two (2) screws in the armrest frame to hold the plastic spacer and the armrest frame together. Refer to the following for service details. 1. Remove the floor console. Refer to the 1994 Service Manual, Section 01-12, for floor console removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Arm Rest: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position > Page 6253 2. Install two (2) screws (381801-S36B) (one on each side) as shown in Figures 1 and 2. 3. Reinstall armrest. Refer to the 1994 Service Manual, Section 01-12, for installation procedures. PART NUMBER PART NAME CLASS 381801-S36B Screw BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941915A Repair Armrest 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 70045A36 33 OASIS CODES: 107000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position Arm Rest: All Technical Service Bulletins Console Armrest - Squeaks In The Down Position Article No. 94-19-15 09/21/94 ^ CONSOLE ARMREST - SQUEAK IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST ^ NOISE - "SQUEAK" - FROM CONSOLE ARMREST IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may experience a "squeak" from the center console armrest when the armrest is down. This may be caused by a plastic spacer rubbing against the metal frame of the armrest. ACTION: Install two (2) screws in the armrest frame to hold the plastic spacer and the armrest frame together. Refer to the following for service details. 1. Remove the floor console. Refer to the 1994 Service Manual, Section 01-12, for floor console removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Technical Service Bulletins > All Other Service Bulletins for Arm Rest: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position > Page 6259 2. Install two (2) screws (381801-S36B) (one on each side) as shown in Figures 1 and 2. 3. Reinstall armrest. Refer to the 1994 Service Manual, Section 01-12, for installation procedures. PART NUMBER PART NAME CLASS 381801-S36B Screw BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941915A Repair Armrest 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 70045A36 33 OASIS CODES: 107000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair Ash Tray: Service and Repair Ash Receptacle and Retainer 1. Open instrument panel ash receptacle to gain access to two retaining screws. 2. Remove the two screws that attach the instrument panel ash receptacle to instrument panel. Remove assembly. 3. Disconnect courtesy lamp feed wire. For installation, follow removal procedures in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Console: Customer Interest Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles Console: Customer Interest Front Seat Center Armrest - Loose/Wobbles Article No. 94-24-10 11/28/94 FRONT SEAT CENTER ARMREST - LOOSE AND WOBBLES - VEHICLES WITH BUCKET SEATS AND FLOOR CONSOLE LIGHT TRUCK: 1989-90 BRONCO II 1989-94 RANGER 1991-94 EXPLORER ISSUE: The front seat center console may become loose and wobble from side to side. This may be caused by the console armrest mounting bracket becoming loose and/or weak under extreme load conditions. ACTION: Replace the center armrest console bracket with a new, more robust center armrest console bracket. Refer to the following for service details. SERVICE PROCEDURE REMOVAL 1. Verify the concern. NOTE: ALSO INSPECT THE ARMREST MOUNTING BRACKET WHICH RETAINS THE ARMREST TO THE CONSOLE. IF THE ARMREST BRACKET IS CONSTRUCTED OF PLASTIC, REFER TO TSB 93-23-19 FOR MORE DETAILS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6275 2. Remove the floor console assembly from the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6276 3. Remove the four (4) nuts retaining the old console armrest mounting bracket to the floor pan. Save the nuts and discard the bracket. Refer to Figure 2. INSTALLATION NOTE: BEFORE PROCEEDING, THE WELD STUDS MUST BE INSPECTED FOR DAMAGE (BENT, STRIPPED, SHEARED). IF ANY OF THESE CONDITIONS EXIST, THE WELD STUD(S) MUST BE REPLACED. REFER TO THE REPLACEMENT OF WELD STUD(S) SERVICE PROCEDURE LOCATED IN THIS ARTICLE BEFORE INSTALLING THE NEW BRACKET. 1. Position the armrest mounting bracket onto the weld studs and tighten nuts to 7-11 N-m (5-8 lb.ft.). Refer to Figure 2. 2. Install the floor console assembly into the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest: > 942410 > Nov > 94 > Front Seat Center Armrest - Loose/Wobbles > Page 6277 3. Verify proper function of the armrest. 4. Following the instructions and precautions on the can, apply SuperSeal (F3AZ-19515-SA) to the affected area to ensure a proper seal. REPLACEMENT OF WELD STUD(S) 1. Use a grinding wheel or equivalent tool to remove damaged weld stud(s) from floor pan. 2. Use a punch and hammer to center punch location of damaged weld stud(s). 3. Drill 1/4 inch diameter hole(s) at center punch mark(s). 4. Insert repair bolt(s) (N606676-S36) and washer(s) through hole(s) and new console bracket from underside of vehicle. 5. Install repair nut(s) (N621905-S2) and torque to 9-11 N-m (6-8 lb.ft.). 6. Refer to the Installation Procedure in this TSB to complete the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: 93-23-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models And Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 942410A Replace Armrest Bracket 0.6 Hr. 942410B Additional Time To Replace 0.2 Hr. One Damaged Weld Stud 942410C Additional Time To Replace 0.3 Hr. Two Or Three Damaged Weld Studs 942410D Additional Time To Replace 0.4 Hr. All Four Damaged Studs DEALER CODING BASIC PART NO. CONDITION CODE 7045C52 01 OASIS CODES: 101000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Console: All Technical Service Bulletins Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles Console: All Technical Service Bulletins Front Seat Center Armrest - Loose/Wobbles Article No. 94-24-10 11/28/94 FRONT SEAT CENTER ARMREST - LOOSE AND WOBBLES - VEHICLES WITH BUCKET SEATS AND FLOOR CONSOLE LIGHT TRUCK: 1989-90 BRONCO II 1989-94 RANGER 1991-94 EXPLORER ISSUE: The front seat center console may become loose and wobble from side to side. This may be caused by the console armrest mounting bracket becoming loose and/or weak under extreme load conditions. ACTION: Replace the center armrest console bracket with a new, more robust center armrest console bracket. Refer to the following for service details. SERVICE PROCEDURE REMOVAL 1. Verify the concern. NOTE: ALSO INSPECT THE ARMREST MOUNTING BRACKET WHICH RETAINS THE ARMREST TO THE CONSOLE. IF THE ARMREST BRACKET IS CONSTRUCTED OF PLASTIC, REFER TO TSB 93-23-19 FOR MORE DETAILS. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6287 2. Remove the floor console assembly from the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6288 3. Remove the four (4) nuts retaining the old console armrest mounting bracket to the floor pan. Save the nuts and discard the bracket. Refer to Figure 2. INSTALLATION NOTE: BEFORE PROCEEDING, THE WELD STUDS MUST BE INSPECTED FOR DAMAGE (BENT, STRIPPED, SHEARED). IF ANY OF THESE CONDITIONS EXIST, THE WELD STUD(S) MUST BE REPLACED. REFER TO THE REPLACEMENT OF WELD STUD(S) SERVICE PROCEDURE LOCATED IN THIS ARTICLE BEFORE INSTALLING THE NEW BRACKET. 1. Position the armrest mounting bracket onto the weld studs and tighten nuts to 7-11 N-m (5-8 lb.ft.). Refer to Figure 2. 2. Install the floor console assembly into the vehicle. Refer to Section 01-12 of the appropriate Service Manual and Figure 1 for installation procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 942410 > Nov > 94 > Front Seat Center Armrest Loose/Wobbles > Page 6289 3. Verify proper function of the armrest. 4. Following the instructions and precautions on the can, apply SuperSeal (F3AZ-19515-SA) to the affected area to ensure a proper seal. REPLACEMENT OF WELD STUD(S) 1. Use a grinding wheel or equivalent tool to remove damaged weld stud(s) from floor pan. 2. Use a punch and hammer to center punch location of damaged weld stud(s). 3. Drill 1/4 inch diameter hole(s) at center punch mark(s). 4. Insert repair bolt(s) (N606676-S36) and washer(s) through hole(s) and new console bracket from underside of vehicle. 5. Install repair nut(s) (N621905-S2) and torque to 9-11 N-m (6-8 lb.ft.). 6. Refer to the Installation Procedure in this TSB to complete the installation procedure. Parts Block OTHER APPLICABLE ARTICLES: 93-23-19 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Models And Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 942410A Replace Armrest Bracket 0.6 Hr. 942410B Additional Time To Replace 0.2 Hr. One Damaged Weld Stud 942410C Additional Time To Replace 0.3 Hr. Two Or Three Damaged Weld Studs 942410D Additional Time To Replace 0.4 Hr. All Four Damaged Studs DEALER CODING BASIC PART NO. CONDITION CODE 7045C52 01 OASIS CODES: 101000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position Console: All Technical Service Bulletins Console Armrest - Squeaks In The Down Position Article No. 94-19-15 09/21/94 ^ CONSOLE ARMREST - SQUEAK IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST ^ NOISE - "SQUEAK" - FROM CONSOLE ARMREST IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may experience a "squeak" from the center console armrest when the armrest is down. This may be caused by a plastic spacer rubbing against the metal frame of the armrest. ACTION: Install two (2) screws in the armrest frame to hold the plastic spacer and the armrest frame together. Refer to the following for service details. 1. Remove the floor console. Refer to the 1994 Service Manual, Section 01-12, for floor console removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position > Page 6294 2. Install two (2) screws (381801-S36B) (one on each side) as shown in Figures 1 and 2. 3. Reinstall armrest. Refer to the 1994 Service Manual, Section 01-12, for installation procedures. PART NUMBER PART NAME CLASS 381801-S36B Screw BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941915A Repair Armrest 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 70045A36 33 OASIS CODES: 107000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Other Service Bulletins for Console: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position Console: All Technical Service Bulletins Console Armrest - Squeaks In The Down Position Article No. 94-19-15 09/21/94 ^ CONSOLE ARMREST - SQUEAK IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST ^ NOISE - "SQUEAK" - FROM CONSOLE ARMREST IN DOWN POSITION - VEHICLES BUILT 6/6/94 THROUGH 6/16/94 WITH CONSOLE ARMREST LIGHT TRUCK: 1994 EXPLORER, RANGER ISSUE: Some vehicles may experience a "squeak" from the center console armrest when the armrest is down. This may be caused by a plastic spacer rubbing against the metal frame of the armrest. ACTION: Install two (2) screws in the armrest frame to hold the plastic spacer and the armrest frame together. Refer to the following for service details. 1. Remove the floor console. Refer to the 1994 Service Manual, Section 01-12, for floor console removal procedures. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Other Service Bulletins for Console: > 941915 > Sep > 94 > Console Armrest - Squeaks In The Down Position > Page 6300 2. Install two (2) screws (381801-S36B) (one on each side) as shown in Figures 1 and 2. 3. Reinstall armrest. Refer to the 1994 Service Manual, Section 01-12, for installation procedures. PART NUMBER PART NAME CLASS 381801-S36B Screw BS OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941915A Repair Armrest 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 70045A36 33 OASIS CODES: 107000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions Console: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6303 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6304 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6305 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6306 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6307 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6308 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6309 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6310 Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams > Diagram Information and Instructions > Page 6311 Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console Console: Service and Repair Floor Console 1. Remove the two oval covers from the sides of the floor console. Remove the four (two on each side) retaining bolts. Lift or remove the front seat center armrest from the floor console. 2. Remove one screw from the top rear end of the floor console (directly under the front seat center armrest. 3. Remove four screws retaining the utility tray beverage holder to floor console. Lift or remove the utility tray beverage holder from the console. 4. Remove two screws (directly under the utility tray beverage holder) retaining the front end of the floor console to the console panel front mounting bracket. 5. Lift the floor console from the front and rear console panel mounting brackets. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 6314 For installation, follow removal procedure in reverse order. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 6315 Console: Service and Repair Floor Console Armrest Mounting Bracket Removal and Installation 1. Remove the floor console assembly. 2. Remove four nuts retaining console panel rear mounting bracket to floor. 3. Lift console panel rear mounting bracket from weld studs. To install, reverse the removal procedure. Tighten nuts to 7-11 N.m (5-8 ft-lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Floor Console > Page 6316 Console: Service and Repair Floor Console Mounting Bracket Removal and Installation 1. Remove console assembly. 2. Remove two nuts retaining console panel front mounting bracket to floor. 3. Lift the console panel front mounting bracket from the weld studs. To install, reverse the removal procedure. Tighten nuts to 7-11 N.m (5-8 ft-lb). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor Headliner: Customer Interest Headliner - Objectionable Odor Article No. 94-10-1 05/18/94 INTERIOR TRIM - OBJECTIONABLE ODOR (FISHY OR MUSTY) FROM HEADLINER FORD: 1992-94 TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1992-94 COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER This TSB article is being republished in its entirety to improve the part descriptions for Aerostar headliner assemblies. ISSUE: An objectionable odor ("fishy" or "musty") may be emitted from the headliner under certain conditions. ACTION: Replace the vehicle headliner with a new low-odor headliner. Refer to the appropriate Service Manual, Section 01-05, for service details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6329 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6330 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6331 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6332 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6333 Parts Block SUPERSEDES: 94-4-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941001A Replace Headliner - 1.1 Hrs. Tempo/Topaz (2 door) 941001B Replace Headliner - 0.9 Hr. Tempo/Topaz (4 door) 941001C Replace Headliner - 0.8 Hr. Taurus/Sable (Sedan) 941001D Replace Headliner - 1.8 Hrs. Taurus/Sable (Wagon) 941001E Replace Headliner - 1.8 Hrs. Thunderbird/Cougar 941001F Replace Headliner - 2.5 Hrs. Aerostar (Front & Rear) 941001G Replace Headliner - 1.5 Hrs. Explorer 941001H Extra Time If Equipped With 0.3 Hr. Sun/Moon Roof Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > Customer Interest for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6334 DEALER CODING BASIC PART NO. CONDITION CODE 7051916 08 OASIS CODES: 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor Headliner: All Technical Service Bulletins Headliner - Objectionable Odor Article No. 94-10-1 05/18/94 INTERIOR TRIM - OBJECTIONABLE ODOR (FISHY OR MUSTY) FROM HEADLINER FORD: 1992-94 TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1992-94 COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1992-94 AEROSTAR, EXPLORER This TSB article is being republished in its entirety to improve the part descriptions for Aerostar headliner assemblies. ISSUE: An objectionable odor ("fishy" or "musty") may be emitted from the headliner under certain conditions. ACTION: Replace the vehicle headliner with a new low-odor headliner. Refer to the appropriate Service Manual, Section 01-05, for service details. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6340 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6341 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6342 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6343 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6344 Parts Block SUPERSEDES: 94-4-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 941001A Replace Headliner - 1.1 Hrs. Tempo/Topaz (2 door) 941001B Replace Headliner - 0.9 Hr. Tempo/Topaz (4 door) 941001C Replace Headliner - 0.8 Hr. Taurus/Sable (Sedan) 941001D Replace Headliner - 1.8 Hrs. Taurus/Sable (Wagon) 941001E Replace Headliner - 1.8 Hrs. Thunderbird/Cougar 941001F Replace Headliner - 2.5 Hrs. Aerostar (Front & Rear) 941001G Replace Headliner - 1.5 Hrs. Explorer 941001H Extra Time If Equipped With 0.3 Hr. Sun/Moon Roof Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headliner: > 94101 > May > 94 > Headliner - Objectionable Odor > Page 6345 DEALER CODING BASIC PART NO. CONDITION CODE 7051916 08 OASIS CODES: 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6351 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6352 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6353 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Programming Connector > Component Information > Locations Keyless Entry Programming Connector: Locations The Program Connector is located under the LH access panel, taped to the wiring harness. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6365 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6366 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Recalls for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6367 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters Technical Service Bulletin # 95B79 Date: 950101 Campaign - Keyless Entry System Transmitters 95B79 OWNER NOTIFICATION PROGRAM Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program Dealer Letter Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Customer Notification Letter Attachment I - Admin./Labor and Parts Information FCSD Contact Talk with your FCSD Parts and Service Zone Manager about program concerns. Claims Enter claims using DWE. See ACESII Manual, Sections 5 & 6. Labor Allowances OPERATION DESCRIPTION HOURS OPERATION Program RKE Transmitters 0.3 Hrs. B79B Parts Requirements There are no parts required for this special owner "mail-in" program. For owners returning with new transmitters and an authorization letter for a free engine oil and filter change claim for the following allowance: ^ Engine Oil and Filter Change Allowance - $25.00 ^ Enter $25.00 in MISC area of the claim as "OTHER" (Includes Labor, Parts and Markup) Claims Preparation Enter using DWE. Use code information shown below: ^ Program Code - 95B79 ^ Labor Operation - B79B See Sections 5 & 6 of the ACESII Manual for detailed instructions. Attachment II - Technical Information Remote Keyless Entry Transmitter Reprogramming NOTE: The reprogramming procedure is basically identical for all vehicles. Exceptions will be identified within each step. Remote Keyless Entry Transmitter Reprogramming 1. Locate the 2-pin RKE programming connector. Refer to RKE Programming Connector Location list below. 2. Turn ignition switch to the RUN position. 3. Using a jumper wire or alligator clip momentarily short the two terminals within the 2-pin program connector. On Econoline models you will need to short these terminals for the duration of the reprogramming procedure. The doors will lock then unlock on all models except Contour and Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6373 Mystique. On Contour and Mystique models only the horn will sound and the exterior lights will flash. 4. Press any button on the remote keyless entry transmitter. All doors will lock then unlock to verify transmitter has been programmed. The horn will sound and the exterior lights will flash on the Contour and Mystique. NOTE: Programming in the first transmitter will erase all other previously programmed transmitters. All transmitters that are to operate with the vehicle (up to four transmitters) must be programmed during Steps 4 and 5. 5. Repeat Step 4 for any additional remote transmitters to be reprogrammed. 6. Turn ignition switch OFF. All doors should lock then unlock. On Contour and Mystique models the horn will sound and the exterior lights will flash. 7. Remove short (Econoline models only). 8. Install any trim previously removed. 9. Verify transmitter operation. RKE Programming Connector Location The Two-Pin RKE Programming Connector Is Located; Taurus/Sable Wagons - behind the left side trim panel inside the cargo area. Remove the trim panel for access to the connector. Taurus/Sable Sedans - Under the left side of the package tray. Contour/Mystique - under the right side of the instrument panel, behind right side of glove compartment. Reach up behind the glove compartment for access to the connector. Probe - in the trunk behind the subwoofer on the right side of the vehicle. Remove the subwoofer (if so equipped) for access to the connector. Mark VIII, Crown Victoria, Grand Marquis and Town Car - behind the glove compartment. Open the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. F-Series and Bronco - under the drivers side of the instrument panel above the drivers right foot area. Mustang - in the trunk behind the left side trim panel. Loosen the lining board (convertibles only) and the rear and left side trim covers to gain access to the connector. Thunderbird/Cougar - behind the left side trim panel inside the trunk. Remove the trim panel for access to the connector. Explorer - behind the left quarter utility compartment access panel. Remove the panel for access to the connector. Windstar - behind and to the right of the glove compartment, compress the sides to allow it to fully open and let it hang for access to the connector. Econoline - under the instrument panel to the left of the steering column. Continental - under the right side of the instrument panel near the glove compartment. Remove the panel from beneath the instrument panel for access to the connector. For further information regarding connector location and color-coding refer to the appropriate Electrical Vacuum and Troubleshooting Manual (EVTM). Dealer Letter To: All Ford and Lincoln-Mercury Dealers Subject: Owner Notification Program 95B79 - Remote Keyless Entry System Transmitters - Special "Mail-In" Service Program OASIS NO Owner List NO Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6374 Parts Return NO Program Terms Available through October 31, 1996 Affected Vehicles 1994-model Continental, Explorer, Crown Victoria, Grand Marquis and Town Car, 1994 and 1995-model Mustang, Taurus, Sable, Thunderbird, Cougar, Mark VIII, Probe, F-Series, Bronco, Econoline and 1995-model Contour, Mystique and Windstar vehicles equipped with the factory installed remote keyless entry system option. (This is the rectangular-shaped transmitter, manufactured by TRW Corp.) Reason For This Program The remote keyless entry system transmitter positive battery terminal contact surface may develop corrosion and result in intermittent transmitter operation and/or unnecessary battery replacement. Service Action Owners of affected vehicles will be notified of a special "mail-in" up-grade program and will be instructed to return their transmitters in a special prepaid mailing envelope. The transmitters will be serviced at a central facility and returned to owners. This bulletin provides instructions if owners should return to dealers for service. Owners will use the special mailing envelope for this special "mail-in" service. However, there are two situations where an owner may contact their dealer: 1.) where the special mailing envelope cannot be located, or 2.) where the central servicing facility was unable to perform the required upgrade of the transmitter for technical reasons. Dealers are required to provide transmitter reprogramming service along with a free engine oil and filter change. In these situations customers will have received an authorization letter along with the new transmitters. Additionally, customers are informed that the authorization letter and the transmitters are to be presented when requesting this service. Limited-Time Program This special "mail-in" program will only be available through October 31, 1996. Special Toll-Free Number for Owner's Questions A special toll-free number is available for owners (1-800-490-4288) from 7:30 a.m. to 7:30 p.m. weekdays and 8:00 a.m. to 3:00 p.m. on Saturdays (All times are Eastern Time). Technical/Administrative Questions? Claims Information 1-800-423-8851 Other Program Questions 1-800-325-5621 Attachments Attachment I ^ Administrative Information ^ Labor Allowances ^ Parts Ordering Information Attachment II ^ Technical Information Owner Letter Serial Number: xxxxxxxxxxxxxxxxx 95B79 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a special no-charge Service Program 95B79 to owners of certain 1994 and 1995-model vehicles equipped with the Ford Remote Keyless Entry System. Reason For This Program: Battery contact corrosion inside the small rectangular shaped Ford Remote Keyless Entry System transmitters (with your vehicle's keys) may cause the system to operate intermittently and possibly result in unnecessary battery replacement. No Charge Service With Drop-In-The-Mailbox Convenience: At no charge to you, Ford Motor Company will upgrade your remote transmitters for Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Transmitter: > 95B79 > Jan > 95 > Campaign - Keyless Entry System Transmitters > Page 6375 proper trouble-free operation via a special mail-in service program. This special mail-in program is designed to provide you with a quick, convenient way to upgrade your remote transmitters and is available to you through October 31, 1996. (If you desire, you could have this service performed by your Ford or Lincoln-Mercury dealer.) Return Transmitters In Special Prepaid Mailer: Use the enclosed prepaid mailing envelope to return all of your remote transmitters for the vehicle identified by the serial number above. Just drop the envelope (with the transmitters enclosed) in the mail. For your security and protection, the prepaid mailer does not require your name or address. The bar-coding on the label will enable us to identify you. Return Only The Transmitters: Please return the remote transmitters only. Detach them from the large key ring. (During the time that your transmitters are being upgraded, remember that you will have to use your key; we apologize for this inconvenience.) Processing Time: Counting mail time to and from our service center, we expect your transmitters will be returned to you within 10 working days. If you have not received your transmitters back by this time, please call the following toll-free number: 1-800-490-4288. Changed Address? Please fill-out the enclosed postcard with your new address and return it in the prepaid mailer with your transmitters. Sold Your Vehicle? Do nothing and discard this communication. Questions? A special toll-free number (1-800-490-4288) is available if you have questions on this program. Ford representatives are available weekdays from 7:30 a.m. to 7:30 p.m. and on Saturdays from 8:00 a.m. to 3:00 p.m. Eastern time. Have your vehicle serial number ready when you call. It is printed above. We are taking this action as part of our on-going efforts to maintain owner confidence in our products. We hope this special mail-in program will confirm your continued satisfaction with your Ford Remote Keyless Entry System. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Page 6376 Keyless Entry Transmitter: Service and Repair Before any of the REMOTE features will operate, the RKE module must be programmed to accept signals from the transmitters. The RKE module may be programmed to accept signals from up to four transmitters. The following steps must be performed in order to program or reprogram the RKE module to respond to the selected transmitters. 1. Put the ignition switch in "RUN" or "ACC" and momentarily jumper the two program connector terminals located under LH quarter access panel. The system will respond by locking and then unlocking all doors. 2. Press any button on the transmitter. All doors will lock and then unlock to verify transmitter signal acceptance. 3. Repeat step 2 in order to program the RKE module to accept up to four transmitter signals. 4. Turn the ignition switch to "OFF". All doors will then lock and unlock. 5. Operate a button on each transmitter to verify that the system has been programmed successfully. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations Power Door Lock Actuator: Locations The Power Door Lock Actuators are located in their respective doors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock Power Door Lock Actuator: Description and Operation Door Lock OPERATION The Door Lock Actuator is a bi-directional motor that will lock or unlock door depending on input of door lock switches. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock > Page 6383 Power Door Lock Actuator: Description and Operation Liftgate Lock OPERATION The Liftgate Lock Actuator is a bi-directional motor that will lock or unlock the liftgate depending on unput of door lock switches. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch Power Door Lock Switch: Diagrams Driver's Master Switch Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6388 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6389 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6390 Power Door Lock Switch: Diagrams Passenger Side Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6391 Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Page 6392 Power Door Lock Switch: Description and Operation OPERATION The Door Lock Switch controls a bi-directional motor by supplying a momentary ground or power to either side of motor depending on position of switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions Heated Element: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 Heated Element: Connector Views LH Power/Heated Mirror LH Power/Heated Mirror RH Power/Heated Mirror Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 Heated Element: Electrical Diagrams Rear Window Defrost/Mirror Defrost Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Rear Window Defrost/Mirror Defrost Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Memory Seat Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 6412 Seat Memory Switch: Description and Operation PURPOSE The Memory Seat Switch is used to recall one of two previously recorded seat positions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Technical Service Bulletins > Recalls for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: Recalls Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: All Technical Service Bulletins Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 6426 Power Mirror Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 6427 Power Mirror Switch: Description and Operation PURPOSE The Power Mirror Switch enables the operator to control the movement of the outside mirrors in either vertical or horizontal directions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal Paint: Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6433 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6434 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6435 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6436 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6437 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6438 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6439 Paint: Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6440 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6441 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6442 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 6443 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Component Locations The Remote Keyless Entry Module is located at left rear quarter panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6448 Keyless Entry Module: Diagrams Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6449 Remote Keyless Entry Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 6450 Keyless Entry Module: Description and Operation OPERATION The Remote Keyless Entry Module monitors dome switch and courtesy lamps switches throughout vehicle. Controls door lock/unlock, liftgate unlock, automatic door lock, arm/disarm anti-theft system, activate/deactivate panel alarm, illuminated entry and battery saver features. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations Power Seat Control Module: Locations Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Locations > Page 6454 Power Seat Control Module: Diagrams Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Recalls for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions Technical Service Bulletin # 97L15 Date: 980301 Recall - Sunroof Instructions 97L15 SAFETY RECALL Safety Recall 97L15 - 1991-1993 Explorer and Owner Notification Program 97L16 - 1993-1994 Explorer Equipped with Optional Factory Installed Flip-Up Open Air Roof (Sunroof) ^ Dealer Letter ^ Attachments not Applicable ^ Customer Notification Letter - 97L15 ^ Customer Notification Letter - 97L16 ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Recalls for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6465 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Recalls for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6466 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Recalls for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6467 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > Recalls for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6468 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions Technical Service Bulletin # 97L15 Date: 980301 Recall - Sunroof Instructions 97L15 SAFETY RECALL Safety Recall 97L15 - 1991-1993 Explorer and Owner Notification Program 97L16 - 1993-1994 Explorer Equipped with Optional Factory Installed Flip-Up Open Air Roof (Sunroof) ^ Dealer Letter ^ Attachments not Applicable ^ Customer Notification Letter - 97L15 ^ Customer Notification Letter - 97L16 ^ Customer Notification Letter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6474 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6475 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6476 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Panel: > 97L15 > Mar > 98 > Recall - Sunroof Instructions > Page 6477 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams Memory Seat Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Diagrams > Page 6483 Seat Memory Switch: Description and Operation PURPOSE The Memory Seat Switch is used to recall one of two previously recorded seat positions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations Power Seat Control Module: Locations Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Locations > Page 6487 Power Seat Control Module: Diagrams Component Locations The Memory Seat Module is located below LH front seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Left Power Bolster & Lumbar Motor Power Seat Motor: Locations Left Power Bolster & Lumbar Motor Component Locations The Left Power Bolster & Lumbar Motor is located under driver's seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Left Power Bolster & Lumbar Motor > Page 6492 Power Seat Motor: Locations Power Lumbar Motor Driver's Component Locations The LH Power Lumbar Motor is located under driver's seat. W/O Memory Seats Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Left Power Bolster & Lumbar Motor > Page 6493 Component Locations The RH Power Lumbar Motor is located under passenger's seat. With Memory Seats Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Left Power Bolster & Lumbar Motor > Page 6494 Component Locations The RH Power Lumbar Motor (with Memory Seat) is located under passenger's seat. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 6499 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 6506 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch Power Door Lock Switch: Diagrams Driver's Master Switch Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6511 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6512 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6513 Power Door Lock Switch: Diagrams Passenger Side Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver's Master Switch > Page 6514 Passenger Door Lock/Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 6515 Power Door Lock Switch: Description and Operation OPERATION The Door Lock Switch controls a bi-directional motor by supplying a momentary ground or power to either side of motor depending on position of switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Recalls for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: Recalls Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Mirror Switch: > NHTSA97V083000 > Apr > 97 > Recall 97V083000: Power Mirror Switch Malfunction Power Mirror Switch: All Technical Service Bulletins Recall 97V083000: Power Mirror Switch Malfunction A short circuit condition can occur in the remote power mirror control switch circuit board as a result of a separated part of the contact assembly bridging the switch positive battery pad and adjacent chassis ground pad. The current can overheat the printed circuit board and other plastic and elastomeric components of the switch assembly resulting in smoke or fire. Dealers will install an in-line 10 amp fuse in the positive battery feed to the remote power mirror control switch assembly. Owner Notification: Owner notification is expected to begin May 19, 1997.Notes: Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-800-424-9393. 1992 FORD TRUCK EXPLORER 1993 FORD TRUCK EXPLORER 1994 FORD TRUCK EXPLORER Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 6529 Power Mirror Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Technical Service Bulletins > Page 6530 Power Mirror Switch: Description and Operation PURPOSE The Power Mirror Switch enables the operator to control the movement of the outside mirrors in either vertical or horizontal directions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams Memory Seat Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Diagrams > Page 6534 Seat Memory Switch: Description and Operation PURPOSE The Memory Seat Switch is used to recall one of two previously recorded seat positions. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6543 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6544 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6545 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6551 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6552 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 6553 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Page 6558 Clutch Switch: Service and Repair 1. Disconnect wiring harness from clutch pedal position switch. 2. Pull orientation clip away from clutch pedal position switch to separate it from pin on switch, then rotate switch to expose white plastic cover. 3. Push tabs together, allowing cover to slide rearward and separate from switch, then remove switch from push rod. 4. Reverse procedure to install. Do not overtighten screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Speed Control Amplifier Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 6562 Cruise Control Module: Service and Repair NOTE: The speed control amplifier is located above the glove box. 1. Open glove compartment and squeeze sides of glove compartment to allow it to rotate down beyond rubber stops. 2. Remove glove compartment courtesy light, then the amplifier and bracket assembly to instrument panel screws. 3. Remove amplifier and bracket assembly from instrument panel. 4. Remove two amplifier screws. 5. Disconnect electrical connectors at amplifier. 6. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams Speed Control Servo Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 6566 Cruise Control Servo: Testing and Inspection Inspect speed control servo assembly for loose or unseated connector pins or broken wires at the connectors. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Diagrams > Page 6567 Cruise Control Servo: Service and Repair 1. Disconnect speed control actuator from accelerator cable. 2. Remove two vacuum hoses and electrical connector from servo assembly. 3. Remove two nuts holding servo to its mounting bracket, then carefully remove servo and speed control actuator. 4. Remove two nuts holding cable cover to servo, then pull off cover and disconnect speed control actuator. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Testing and Inspection Cruise Control Servo Cable: Testing and Inspection Inspect Bowden cable for improper adjustment, then readjust as required. Check for broken actuator cable. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Testing and Inspection > Page 6571 Cruise Control Servo Cable: Adjustments 1. Remove cable retaining clip, then disengage throttle positioner. 2. Set throttle to hot idle position. 3. Pull on actuator cable to take up all slack, then, while holding cable in this position, install cable retaining clip. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair 1. Disconnect ground cable at rechargeable telephone power pack battery, then remove steering wheel horn pad attaching screws. 2. Lift horn pad from steering wheel and remove connector from steering wheel horn pad. 3. Remove and discard steering wheel attaching bolt, then remove steering wheel from upper shaft using steering wheel puller tool No. T67L-3600-A, or equivalent. 4. Remove steering column lower trim shroud, then the straps securing brush assembly wire at ignition switch and column tube. 5. Remove screw attaching speed control brush to upper bearing retainer plate, then the speed control brush assembly wire and connector assembly through opening in upper bearing retainer plate. 6. Clean all old grease from slip rings and speed control brush, then apply new coat of Speed Control Slip Ring Grease part No. E8AZ-19590-A, or equivalent. 7. Reverse procedure to install, noting the following: a. Route brush wire so it does not interfere with trim shroud installation and is not pierced by retaining screws. b. Align index mark on steering wheel with index mark on shaft. c. Install new steering wheel bolt. Torque steering wheel bolt to 23-33 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams Cruise Control Module: Diagrams Speed Control Amplifier Speed Control Amplifier Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Diagrams > Page 6579 Cruise Control Module: Service and Repair NOTE: The speed control amplifier is located above the glove box. 1. Open glove compartment and squeeze sides of glove compartment to allow it to rotate down beyond rubber stops. 2. Remove glove compartment courtesy light, then the amplifier and bracket assembly to instrument panel screws. 3. Remove amplifier and bracket assembly from instrument panel. 4. Remove two amplifier screws. 5. Disconnect electrical connectors at amplifier. 6. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams Clutch Triple Function Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Diagrams > Page 6584 Clutch Switch: Service and Repair 1. Disconnect wiring harness from clutch pedal position switch. 2. Pull orientation clip away from clutch pedal position switch to separate it from pin on switch, then rotate switch to expose white plastic cover. 3. Push tabs together, allowing cover to slide rearward and separate from switch, then remove switch from push rod. 4. Reverse procedure to install. Do not overtighten screws. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair Cruise Control Switch: Service and Repair 1. Disconnect ground cable at rechargeable telephone power pack battery, then remove steering wheel horn pad attaching screws. 2. Lift horn pad from steering wheel and remove connector from steering wheel horn pad. 3. Remove and discard steering wheel attaching bolt, then remove steering wheel from upper shaft using steering wheel puller tool No. T67L-3600-A, or equivalent. 4. Remove steering column lower trim shroud, then the straps securing brush assembly wire at ignition switch and column tube. 5. Remove screw attaching speed control brush to upper bearing retainer plate, then the speed control brush assembly wire and connector assembly through opening in upper bearing retainer plate. 6. Clean all old grease from slip rings and speed control brush, then apply new coat of Speed Control Slip Ring Grease part No. E8AZ-19590-A, or equivalent. 7. Reverse procedure to install, noting the following: a. Route brush wire so it does not interfere with trim shroud installation and is not pierced by retaining screws. b. Align index mark on steering wheel with index mark on shaft. c. Install new steering wheel bolt. Torque steering wheel bolt to 23-33 ft lb. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Adjustments Vacuum Vent Valve: Adjustments Fig. 25 Vacuum Dump Valve Adjustment 1. Move valve forward in retaining clip with valve plunger contacting brake pedal adapter and pedal in released position until 0.050 (1/8 inch) or less of the plunger shows. 2. Ensure brake pedal is against stop in release position after adjustment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions ABS Light: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6596 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6597 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6598 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6599 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6600 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6601 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6602 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Diagram Information and Instructions > Page 6603 ABS Light: Electrical Diagrams BRAKE WARNING LIGHT Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Diagrams > Page 6604 ABS Light: Testing and Inspection BRAKE WARNING LIGHT ON POSSIBLE SOURCE(S): ^ Low fluid level. ACTION(S)TO TAKE: ^ Add fluid, check for leaks, and perform system brake bleeding if required. POSSIBLE SOURCE(S): ^ Parking brake applied or not returning completely. ACTION(S)TO TAKE: ^ Release parking brake. POSSIBLE SOURCE(S): ^ Shorted light circuit. ACTION(S)TO TAKE: ^ Correct short in warning circuit. POSSIBLE SOURCE(S): ^ Damaged fluid level switch or float assembly. ACTION(S)TO TAKE: ^ Replace plastic reservoir assembly. POSSIBLE SOURCE(S): ^ Anti-Lock light does self check. ACTION(S)TO TAKE: ^ Refer to Anti-lock Brakes. See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures POSSIBLE SOURCE(S): ^ Damaged combination valve. ACTION(S)TO TAKE: ^ Replace as required. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6609 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6610 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6611 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6612 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6613 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6614 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6615 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6616 Audible Warning Device: Electrical Diagrams Warning Chime Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 6617 Warning Chime Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Chime Module: Locations Component Locations The Warning Buzzer/Chime Module is located in RH side of Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 6621 Warning Buzzer/Chime Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation PURPOSE To alert the vehicle operator of a charging system malfunction when the charge at the alternator falls below the normal operating range. OPERATION When the ignition switch is in START or RUN position, battery current flows through the alternator warning indicator into regulator at terminal 1 and to ground through the indicator switch. The electronic control measures a low voltage at terminal A and closes the field switch. This applies battery voltage to the field through alternator terminal F. With current in the field and the rotor turning, alternator stator produces a voltage at terminals B and S. A predetermined voltage at terminal S operates the electronic control to open indicator switch, which removes ground from alternator warning indicator. Alternator current output is controlled by current in the field. Average field current depends on length of time field switch is closed. The electronic control closes field switch when voltage at terminal A is low and opens switch when voltage is high. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions Cigar Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6629 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6630 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6631 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6632 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6633 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6634 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6635 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Diagrams > Diagram Information and Instructions > Page 6636 Horn/Cigar Lighter Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Cigar Lighter: Initial Inspection and Diagnostic Overview Inspect cigar lighter for obvious damage. Also clean cigar lighter knob and element and socket. Press cigar lighter knob and element in to verify inoperative lighter concern. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6639 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigar Lighter <--> [Cigarette Lighter] > Component Information > Testing and Inspection > Page 6640 Cigar Lighter: Service and Repair 1. Disconnect battery ground cable. 2. Remove cigar lighter knob and element. 3. Remove instrument panel ash receptacle from instrument panel. Disconnect cigar lighter wire from base. 4. Unscrew cigar lighter socket and retainer. For installation, follow removal procedures in reverse order. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > Customer Interest for Compass: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Compass: Customer Interest Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compass: > 96815 > Apr > 96 > Compass/Map Light Erratic Operation/Burned Out Compass: All Technical Service Bulletins Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Four Wheel Drive Indicator Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6662 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6663 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6664 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6665 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6666 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6667 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6668 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6669 Electric Shift Control Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation This fuel level indicating system consists of a sending unit attached to the fuel tank and a fuel gauge mounted on the instrument panel. The magnetic fuel indicator gauge creates a polarity in the wire windings which, depending on the resistance at the sender, controls the degree of pointer rotation. This gauge operates on battery voltage. The fuel sender consists of a variable resistor, controlled by the action of an attached float in the fuel tank. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation PURPOSE To supply an electrical signal to operate the fuel gauge. OPERATION The Sender is a variable resistor connected to a float in the fuel tank, which determines the amount of fuel in tank. When fuel is low, resistance is low (22.5 ohms); when fuel is high, resistance is high (145 ohms). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair Air Bag(s) Arming and Disarming: Service and Repair Deactivation Procedure 1. Disconnect positive battery cable. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. 2. Wait one minute. This is the time required for backup power supply in air bag diagnostic monitor to deplete its stored energy. 3. Remove four nut and washer assemblies retaining driver side air bag module to steering wheel. 4. Disconnect driver air bag connector. Remove driver side air bag module from vehicle. WARNING: Place air bag module on bench with trim cover facing up. 5. Connect Rotunda Air Bag Simulator or equivalent to vehicle harness at top of steering column. 6. Reconnect positive battery cable. Reactivation Procedure 1. Disconnect positive battery cable. 2. Wait one minute for backup power supply in air bag diagnostic monitor to deplete stored energy. 3. Remove Rotunda Air Bag Simulator or equivalent from vehicle harness connector at top of steering column. Reconnect driver side air bag module. WARNING: The air bag simulator must be removed and the air bag reconnected when the system is reactivated. 4. Position driver side air bag module on steering wheel and secure with four nut and washer assemblies (10 mm). Tighten screw and washer assemblies to 4.0-6.0 Nm (36-53 lb in). 5. Reconnect positive battery cable. 6. Prove out system. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised Malfunction Indicator Lamp: Technical Service Bulletins Connector, DIS Ignition Revised ARTICLE NO. 95-10-2 05/22/95 ^ IGNITION CONTROL MODULE (ICM) - REVISED CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEMS (DIS) ONLY ^ LAMP - "MALFUNCTION INDICATOR LAMP" (MIL) ILLUNINATED - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION CLIP AND SEAL - DISTRIBUTORLESS IGNITION SYSTEM (DIS) ONLY ^ WIRING - REVISED IGNITION CONTROL MODULE (ICM) CONNECTOR RETENTION DUSTRUBUTORLESS IGNITION SYSTEM (DIS) ONLY FORD: 1991-94 ESCORT 1992-94 CROWN VICTORIA 1993-94 TAURUS 1994 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1990-94 TOWN CAR 1991-94 TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII 1994 COUGAR LIGHT TRUCK: 1990-94 AEROSTAR, RANGER 1991-94 EXPLORER ISSUE: Some vehicles may have a disconnect of the Ignition Control Module (ICM) connector or moisture buildup within the connector. This can cause hard to start/no start, rough idle, or "check engine light" illumination concerns. The improved gasket and connector retainer that are currently used in production are now available for service of prior model distributorless ignition systems. ACTION: Install new Connector Sleeve Retainer Clip and a current production seal (gasket). The clip assembles in between the connector beams and the ICM which will prevent accidental disconnects. The new seal is a "solid silicone" gasket that provides improved resistance to moisture entry into the connector. Refer to the ICM Connector Harness Wire Service kit (F5CZ-14A411-AA) for service details (I.S. 6621). AFFECTED ENGINES ^ Escort/Tracer - 1.9L ^ Crown Victoria/Grand Marquis/Town Car/Mark VIII- 4.6L ^ Taurus Flex Fuel, California - 3.0L ^ Mustang - 3.8L ^ Thunderbird/Cougar - 3.8L SC, 3.8L California only, and 4.6L ^ Aerostar/Explorer/Ranger - 4.0L The Ignition Control Module (ICM) Connector Harness Wire Service Kit (F5CZ-14A411-AA) contains the following components: ^ One (1) Gasket - Wire Seal ^ One (1) Retainer - Wire Connector Sleeve (Clip) ^ One (1) Instruction Sheet (I.S. 6621) PART NUMBER PART NAME F5CZ-14A411-AA ICM Connector Harness Wire Service Kit OTHER APPLICABLE ARTICLES: NONE Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Connector, DIS Ignition Revised > Page 6684 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Or Emissions Warranty Coverage For All Others OPERATION DESCRIPTION TIME 951002A Install kit 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 12A581 94 12A581 H2 OASIS CODES: 203000, 206000, 602300, 603300, 608400, 698298 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Technical Service Bulletins > Page 6685 Malfunction Indicator Lamp: Description and Operation PURPOSE To alert the vehicle operator of a malfunction in the electronic engine control system. OPERATION The Malfunction Indicator will light with the ignition switch in the ON position prior to cranking, and goes out when the engine starts. If a fault develops, the powertrain control module will turn the indicator ON. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation Oil Level Warning Indicator: Description and Operation PURPOSE To alert the vehicle operator that the engine oil level is low. COMPONENTS The system consists of a float-type sensor mounted to the side of the engine oil pan, an electronic control module, and an instrument panel warning lamp. OPERATION The Check Oil Indicator will light with ignition switch in the START position as a bulb prove-out. When ignition switch is turned to RUN or START position, the control module determines whether sensor is grounded (oil low) or ungrounded (oil not low). If oil level is adequate, light will go out in RUN. If oil level is approximately 1.5 quarts or more low, the relay turns the warning lamp ON. The lamp will remain ON until ignition is turned OFF. After ignition is turned OFF, module will not reset for approximately five minutes. This delay allows time for oil drain back before another reading is allowed to occur. If engine is restarted during this delay period, the last reading will be displayed. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Description and Operation > Page 6689 Oil Level Warning Indicator: Testing and Inspection With oil level at FULL mark on oil dipstick and engine oil warm to assure that oil drains properly from oil sensor, turn ignition ON and start engine. Warning lamp should come on briefly in START for bulb test, then go out. Turn engine OFF. Drain two quarts of oil from engine. Wait approximately five minutes, then restart engine. Warning lamp should come on and stay on. If warning lamp does not come on check fuse, low oil level relay, low oil level sensor and lamp. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates to align to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests Oil Pressure Gauge: Pinpoint Tests Oil Pressure Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Oil Pressure Gauge Inaccurate Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 6698 Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 6699 Oil Pressure Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations Oil Pressure Switch: Component Locations All Except Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 6704 Limited Edition And Electronic Group Left Hand Side Of Engine, Next To Power Steering Pump Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations > Component Locations > Page 6705 Oil Pressure Switch: Connector Locations Left Hand Side Of Engine, Next To Power Steering Pump Oil Pressure Sending Unit Connector # C175 .............................................................................................................................................................. ....... Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when engine is idling, even though oil pressure is adequate. However, light should go out when engine speed is increased. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions Outside Temperature Display: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6713 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6714 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6715 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6716 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6717 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6718 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6719 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6720 Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Diagrams > Diagram Information and Instructions > Page 6721 Overhead Console Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations Warning Chime Module: Locations Component Locations The Warning Buzzer/Chime Module is located in RH side of Instrument Panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Warning Chime Module <--> [Audible Warning Device Control Module] > Component Information > Locations > Page 6729 Warning Buzzer/Chime Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Oil Level Warning Indicator Relay > Component Information > Locations Oil Level Warning Indicator Relay: Locations Component Locations The Low Oil Level Relay is located in LH side of dash panel, above interior fuse panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Description and Operation Fuel Gauge Sender: Description and Operation PURPOSE To supply an electrical signal to operate the fuel gauge. OPERATION The Sender is a variable resistor connected to a float in the fuel tank, which determines the amount of fuel in tank. When fuel is low, resistance is low (22.5 ohms); when fuel is high, resistance is high (145 ohms). Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation Parking Brake Warning Switch: Description and Operation PURPOSE To provide an electrical signal to illuminate the parking brake warning lamp. OPERATION The switch is closed with parking brake applied. When closed, ground is applied to illuminate the brake indicator. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > RPM Test Connector <--> [Tachometer Connector] > Component Information > Locations RPM Test Connector: Locations TACHOMETER SERVICE CONNECTOR LOCATION RH rear of engine compartment, near blower motor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate Temperature Gauge: Customer Interest Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 6752 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 6753 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate Temperature Gauge: All Technical Service Bulletins Temperature Gauge - Fluctuation/Inaccurate Article No. 95-18-5 09/11/95 TEMPERATURE GAUGE - FLUCTUATING AND/OR INACCURATE HIGH READINGS FORD: 1990-94 TAURUS, THUNDERBIRD 1991-93 TEMPO 1991-94 ESCORT LINCOLN-MERCURY: 1990-94 COUGAR SABLE 1991-93 TOPAZ 1991-94 TRACER LIGHT TRUCK: 1990-91 AEROSTAR 1990-94 RANGER 1991-94 EXPLORER This TSB article is being republished in its entirety to correct model year application and revise the part descriptions. ISSUE: Some vehicles may show temperature gauge fluctuations and/or inaccurate (high) readings (affected engines are 3.0L/4.0L Ranger. 4.0L Explore and 1.9L Escort/Tracer). The inaccurate (high) readings may result in a customer concern with the perception of engine overheating. This is caused by Gauge/Sender design characteristics which create a sensitive gauge indication. ACTION: Replace the gauge and sender with a new Temperature Indication Service Kit. Refer to the following for Additional Concerns and Service Procedure for details. ADDITIONAL CONCERNS Please verify the following two (2) concerns before implementing the fix for the above concern. 1. Perform cooling system diagnosis per TSB 93-24-8. 2. Vehicles built from 1/1/93 to 4/1/93 may experience high temperature gauge indications which may have been due to the installation of improperly manufactured temperature sending units. The customer concern is that the gauge indication is beyond the letter "L" in the word "NORMAL". If this condition occurs, inspect the temperature sender for an "A3" stamped date code on the hex of the sending unit. If an "A3" unit is found, replace with "NON-A3" service stock. 3. 1993 Taurus/Sable 3.8L vehicles built 8/16/93 to 8/31/93 may have high temperature gauge readings caused by an incorrect temperature sending unit installed at the assembly plant. The incorrect temperature sending unit can be identified by a blue insulator around the terminal. The correct temperature sending unit has a green insulator. If a temperature sending unit with a blue insulator is found, replace it with an F1SZ-10884-A. 4. Explorer 4.0L vehicles with date code 2204 to 2274 should not be used. Any other date code outside this is acceptable even with an "A3" stamp. NOTE: DATE CODES ARE BASED ON THE JULIAN DATE CODE SYSTEM. THE LAST NUMBER DENOTES THE YEAR THAT THE PART WAS MANUFACTURED. FOR EXAMPLE, 2274 (1994 PART) AND 2275 (1995 PART). ANY 1995 PART MAY BE USED. TEMPERATURE INDICATION SERVICE KIT PROCEDURE NOTE: THIS PROCEDURE IS PERFORMED AFTER THE ABOVE TWO (2) STEPS HAVE BEEN DONE. The installation of the service kit will result in a pointer indicating in the approximate center of the "NORMAL" band while providing protection for a boil-over condition. The service kit consists of: Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 6759 ^ Instructions ^ Temperature Gauge ^ Temperature Sender The instructions will contain the following steps: 1. Remove BOTH existing temperature sender and temperature gauge from the vehicle. NOTE: REFER TO SECTION 13, CONVENTIONAL INSTRUMENT CLUSTER, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE GAUGE REMOVAL AND INSTALLATION INSTRUCTIONS. REFER TO SECTION 03-03, COOLING SYSTEM, OF THE APPROPRIATE SERVICE MANUAL FOR TEMPERATURE SENDER REMOVAL AND INSTALLATION PROCEDURES. 2. Install BOTH service kit temperature sender and temperature gauge into the vehicle. NOTE: THE SERVICE KIT TEMPERATURE SENDER AND TEMPERATURE GAUGE MUST BE USED TOGETHER. Parts Block OTHER APPLICABLE ARTICLES: 93-24-8 SUPERSEDES: 95-15-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 951805A Replace Temperature 1.0 Hr. Gauge And Sending Unit - Taurus/Sable, Tempo/Topaz, Thunderbird/Cougar, Explorer, Ranger, Aerostar (4X2) 951805B Replace Temperature 1.1 Hr. Gauge And Sending Unit - Escort/Tracer 951805C Replace Temperature 1.2 Hrs. Gauge And Sending Unit - Aerostar (4X4) DEALER CODING Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 95185 > Sep > 95 > Temperature Gauge - Fluctuation/Inaccurate > Page 6760 CONDITION BASIC PART NO. CODE 10883 79 10884 79 OASIS CODES: 204000, 204200, 206000, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Page 6761 Temperature Gauge: Description and Operation Fig. 8 Magnetic Guage The magnetic gauge movement consists of three primary coils, one of which is wound at a 90 degree angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet which is attached to a shaft and pointer rotates and aligns to this primary field resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which is attached to the instrument cluster. These gauges require no adjustments, calibrations or maintenance. This gauge system does not use an IVR. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests Temperature Gauge: Pinpoint Tests Temperature Gauge Inaccurate Troubleshooting Chart, Temperature Or Oil Gauge Inaccurate. Temperature Gauge Inoperative Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 6764 Troubleshooting Chart, Temperature Or Oil Gauge Inoperative. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 6765 Temperature Gauge: Component Tests and General Diagnostics TROUBLESHOOTING Tester tool No. 021-00055 or equivalent should be used to diagnose these type of gauges. When troubleshooting, refer to pertaining pinpoint test. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Temperature Gauge - Reads Low/Erratic > Page 6770 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation PURPOSE The Voltmeter displays the current battery/charging system voltage to the driver. OPERATION The Voltmeter measures the electrical flow from the battery to indicate whether the battery output is within tolerances. The voltmeter reading can range from 13.5-14.0 volts under normal operating conditions. If an undercharge or overcharge condition is indicated for an extended period, the battery and charging system should be checked. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Testing and Inspection Backup Lamp Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations > Left Brake Lamp Relay: Locations Left Component Locations The LH Stop Relay is located in LH rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations > Left > Page 6784 Brake Lamp Relay: Locations Right Component Locations The RH Stop Relay is located at left rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Diagrams > Right > Page 6787 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation PURPOSE The Brake On/Off (BOO) signal is received by the Powertrain Control Module (PCM) when the brakes are APPLIED. The PCM uses this signal to modify the operation of the Torque Converter Clutch (TCC) (if equipped), A/C compressor (if equipped), and idle speed during periods of decel and idle with the brakes APPLIED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6791 Brake Light Switch: Service and Repair REMOVAL Fig. 9 Stop Light Switch Replacement 1. Disconnect electrical connector from switch, Fig. 9. 2. Remove hairpin clip, then slide switch, pushrod, nylon washer and bushings away from pedal. 3. Remove washer, then the switch by sliding switch up or down. INSTALLATION 1. Position switch so that U-shaped side is nearest pedal and directly over or under pin. 2. Slide switch up or down, trapping vacuum booster input rod and bushing between switch side plates. 3. Push switch and pushrod assembly toward brake pedal arm, then assemble plastic washer to pin and install hairpin clip to retain assembly. 4. Connect electrical connector to switch, then check for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 Courtesy Lamp: Electrical Diagrams Courtesy Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 Courtesy Lamps With Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 Courtesy Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 Courtesy Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 Courtesy Lamps Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations All Except Limited Edition And Electronic Group The Daytime Running Lamps (DRL) Module is located at the LH front corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6812 Daytime Running Lamps (DRL) Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations Fog Lamp Relay: Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6817 Component Locations The Fog Lamp Relay is located at the center of the instrument panel, above Warning Buzzer/Chime Module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6818 Fog Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6819 Fog Lamp Relay: Description and Operation OPERATION The Fog Lamp Relay directs power to light the fog lamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Fog Lamps <--> [Fog/Driving Lamp] > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 6823 Fog/Driving Lamp Switch: Description and Operation PUPOSE The Fog Lamp Switch directs power to energize the fog lamp relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations These models use the same flasher for both turn signal and hazard indicator operation. It is located behind the instrument panel steering column cover, on the lefthand side of the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6831 Hazard Warning Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 6832 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation PURPOSE The Headlamp Dimmer Switch allows vehicle operator to select high/low beam headlamp operation or the flash-to-pass feature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 6837 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 6838 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only Headlamp Switch: Testing and Inspection All Except Limited Edition and Electronic Group Only Component Testing Procedure Terminal Location On Switch Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only > Page 6843 Headlamp Switch: Testing and Inspection Limited Edition and Electronic Group Only Component Testing Procedure Headlamp Switch (Limited/Electronic) Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Testing and Inspection > Page 6844 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable, remove ash tray assembly and two finish panel retaining screws, then the finish panel (snaps off). 2. Remove rear window wash/wipe and heated rear light switch assembly (snaps out). Fig. 11 Headlamp Switch Replacement. 3. Pull headlamp switch knob to ON position, then depress shaft release button on switch and remove knob and shaft assembly. 4. Remove bezel nut, pull switch down through opening, disconnect electrical connector, then remove switch. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation PURPOSE To alert the vehicle operator that the high beam headlamps are ON. OPERATION The High Beam Indicator will light when the headlamps are put into high beam position with the headlamp dimmer switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Component Locations The Horn Relay is located at the center of Instrument Panel, right of steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 6852 Horn Relay: Description and Operation PURPOSE The Horn Relay provides power to horns. OPERATION When the Horn Relay is energized, it directs voltage to sound high and low pitch horns. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > Customer Interest for Map Light: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Map Light: Customer Interest Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Map Light: > 96815 > Apr > 96 > Compass/Map Light - Erratic Operation/Burned Out Map Light: All Technical Service Bulletins Compass/Map Light - Erratic Operation/Burned Out Article No. 96-8-15 04/08/96 ^ COMPASS - ERRATIC - VEHICLES BUILT THROUGH 2/1/96 ^ LAMP - MAP LAMP BULB BURN OUT - VEHICLES BUILT THROUGH 2/1/96 ^ SWITCH - MAP LAMP OPERATION ERRATIC - VEHICLES BUILT THROUGH 2/1/96 LIGHT TRUCK: 1993-96 EXPLORER 1994-96 BRONCO ISSUE: Map lamp switch and/or overhead compass function operation is irregular, and/or map lamp bulbs may burn out on some vehicles. Installation of revised parts should resolve this issue. ACTION: Replace the map lamp, switch, compass and wiring harness with a revised Overhead Console Kit (F67Z-78519C42-AA). Refer to Instruction Sheet # 7151, included with the kit, for service procedure. The Overhead Console kit (F67Z-7851 9C42-AA) includes the following: ^ One (1) Map Lamp Assembly ^ One (1) Map Lamp Button ^ One (1) Compass ^ One (1) Wiring Harness ^ One (1) Modification Label ^ One (1) Instruction Sheet (I.S. # 7151) PART NUMBER PART NAME F67Z-78519C42-AA Overhead Console Kit OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 960815A Replace Map Lamp And 0.3 Hr. Console Assembly DEALER CODING CONDITION BASIC PART NO. CODE 13776 42 19A548 42 OASIS CODES: 201000, 201100, 203000, 204000, 205000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Left Brake Lamp Relay: Locations Left Component Locations The LH Stop Relay is located in LH rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Left > Page 6871 Brake Lamp Relay: Locations Right Component Locations The RH Stop Relay is located at left rear quarter panel. This relay is only used on vehicles with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Diagrams > Right > Page 6874 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations All Except Limited Edition And Electronic Group The Daytime Running Lamps (DRL) Module is located at the LH front corner of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations > Page 6878 Daytime Running Lamps (DRL) Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations Fog Lamp Relay: Locations Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6882 Component Locations The Fog Lamp Relay is located at the center of the instrument panel, above Warning Buzzer/Chime Module. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6883 Fog Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog Lamp Relay <--> [Fog/Driving Lamp Relay] > Component Information > Locations > Page 6884 Fog Lamp Relay: Description and Operation OPERATION The Fog Lamp Relay directs power to light the fog lamps. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Component Locations The Horn Relay is located at the center of Instrument Panel, right of steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 6888 Horn Relay: Description and Operation PURPOSE The Horn Relay provides power to horns. OPERATION When the Horn Relay is energized, it directs voltage to sound high and low pitch horns. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Component Locations The Tail Lamp Relay is located at left rear quarter panel. This relay is only used on models equipped with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 6892 Tail Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Left Turn Signal Relay: Locations Left Component Locations The LH Turn Signal Relay is located in LH rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Locations > Left > Page 6897 Turn Signal Relay: Locations Right Component Locations The RH Turn Signal Relay is located at left rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Diagrams > Right > Page 6900 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Testing and Inspection Backup Lamp Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation Brake Light Switch: Description and Operation PURPOSE The Brake On/Off (BOO) signal is received by the Powertrain Control Module (PCM) when the brakes are APPLIED. The PCM uses this signal to modify the operation of the Torque Converter Clutch (TCC) (if equipped), A/C compressor (if equipped), and idle speed during periods of decel and idle with the brakes APPLIED. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 6908 Brake Light Switch: Service and Repair REMOVAL Fig. 9 Stop Light Switch Replacement 1. Disconnect electrical connector from switch, Fig. 9. 2. Remove hairpin clip, then slide switch, pushrod, nylon washer and bushings away from pedal. 3. Remove washer, then the switch by sliding switch up or down. INSTALLATION 1. Position switch so that U-shaped side is nearest pedal and directly over or under pin. 2. Slide switch up or down, trapping vacuum booster input rod and bushing between switch side plates. 3. Push switch and pushrod assembly toward brake pedal arm, then assemble plastic washer to pin and install hairpin clip to retain assembly. 4. Connect electrical connector to switch, then check for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams Fog Lamp Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Diagrams > Page 6912 Fog/Driving Lamp Switch: Description and Operation PUPOSE The Fog Lamp Switch directs power to energize the fog lamp relay. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 6916 Hazard Warning Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 6917 Hazard Warning Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation Headlamp Dimmer Switch: Description and Operation PURPOSE The Headlamp Dimmer Switch allows vehicle operator to select high/low beam headlamp operation or the flash-to-pass feature. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 6921 Headlamp Dimmer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 6922 Headlamp Dimmer Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only Headlamp Switch: Testing and Inspection All Except Limited Edition and Electronic Group Only Component Testing Procedure Terminal Location On Switch Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > All Except Limited Edition and Electronic Group Only > Page 6927 Headlamp Switch: Testing and Inspection Limited Edition and Electronic Group Only Component Testing Procedure Headlamp Switch (Limited/Electronic) Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Testing and Inspection > Page 6928 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable, remove ash tray assembly and two finish panel retaining screws, then the finish panel (snaps off). 2. Remove rear window wash/wipe and heated rear light switch assembly (snaps out). Fig. 11 Headlamp Switch Replacement. 3. Pull headlamp switch knob to ON position, then depress shaft release button on switch and remove knob and shaft assembly. 4. Remove bezel nut, pull switch down through opening, disconnect electrical connector, then remove switch. 5. Reverse procedure to install. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6932 Turn Signal Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 6933 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 6938 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations Tail Lamp Relay: Locations Component Locations The Tail Lamp Relay is located at left rear quarter panel. This relay is only used on models equipped with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Lamp Relay > Component Information > Locations > Page 6943 Tail Lamp Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations These vehicles use the same flasher for both turn signal and hazard indicator operation. It is located behind the instrument panel steering column cover, on the lefthand side of the steering column. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Left Turn Signal Relay: Locations Left Component Locations The LH Turn Signal Relay is located in LH rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Locations > Left > Page 6952 Turn Signal Relay: Locations Right Component Locations The RH Turn Signal Relay is located at left rear quarter panel. This relay is only used on models with trailer package. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Right RH Stop/Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams > Right > Page 6955 LH Stop/Turn Relay Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams Turn/Hazard Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6959 Turn Signal Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 6960 Turn Signal Switch: Service and Repair REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 6966 OASIS CODES: 201000, 201200 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Rear Window Defroster <--> [Heated Glass Element] > Heated Glass Element Switch > Component Information > Diagrams Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views Power Window Control Module: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 6977 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 6978 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 6979 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 6980 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Full Body Views > Page 6981 Power Window Control Module: Locations One Touch Down Power Window Module Component Locations The One-Touch Module is located in LF door panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control Module > Component Information > Locations > Page 6982 One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Heated Rear Window Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views Power Window Switch: Locations Behind Instrument Panel Views All Except Limited Edition And Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6991 Component Locations Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6992 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6993 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6994 Power Window Switch: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6995 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6996 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6997 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 6998 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Power Window Switch: Connector Views Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Power Window Switch: Electrical Diagrams Power Windows (2 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Power Windows (4 Door) Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel Power Window Circuit Breaker: Locations Interior Fuse Panel Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel > Page 7021 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel > Page 7022 Power Window Circuit Breaker: Locations All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel > Page 7023 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel > Page 7024 Power Window Circuit Breaker: Locations Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations > Interior Fuse Panel > Page 7025 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Power Window Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7028 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7029 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7030 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7031 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7032 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7033 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7034 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7035 Power Window Circuit Breaker: Electrical Diagrams Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7036 Interior Fuse Panel/Circuits Protector Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7037 Power Windows (2 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7038 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7039 Power Windows (4 Door) Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7040 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7041 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views Power Window Control Module: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views > Page 7046 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views > Page 7047 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views > Page 7048 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views > Page 7049 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Full Body Views > Page 7050 Power Window Control Module: Locations One Touch Down Power Window Module Component Locations The One-Touch Module is located in LF door panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information > Locations > Page 7051 One-Touch Module Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views Power Window Motor: Locations Behind Instrument Panel Views All Except Limited Edition And Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7056 Component Locations Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7057 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7058 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7059 Power Window Motor: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7060 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7061 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7062 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Behind Instrument Panel Views > Page 7063 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions Power Window Motor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Power Window Motor: Electrical Diagrams Power Windows (2 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 Power Windows (4 Door) Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7076 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7077 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Page 7078 Power Window Motor: Description and Operation PURPOSE To electrically raise and lower the side window glass. OPERATION The Power Window Motor is a bi-directional electric motor that will lower or raise window depending on position of power window switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door Power Window Motor: Service and Repair Front Door Removal 1. Raise the window to the full-up position, if possible. If the glass cannot be raised and is in a partially down position, it must be supported so that it will not fall into the door well during motor removal. 2. Disconnect battery ground cable. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 3. Remove door trim panel and watershield. 4. Disconnect window motor connector. 5. Position the motor wiring harness out of the way. There are two holes and one drill dimple located on the door inner panel adjacent to the motor. CAUTION: Prior to motor removal, make sure that the regulator arm is in a fixed position to prevent counterbalance spring unwind. 6. Remove the three window motor mounting screws and disengage the motor and drive assembly from the regulator quadrant gear. Installation 1. Position the motor and drive to the regulator and install the three screws snug, not tight. 2. Connect the motor wires at the connector and cycle the glass to ensure gear engagement. After the gears are engaged, tighten the three motor and drive attaching screws to 5.6-9.6 N-m (50-84 in-lb). 3. Install the door trim panel and watershield. Refer to «Section 01-05B». Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 7081 NOTE: Appropriate plug buttons may be installed to cover the exposed hole at the trim panel edge, if necessary. 4. Connect battery ground cable. 5. Check the drain holes at the bottom of the doors to ensure that each is open to prevent water buildup over the motor. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 7082 Power Window Motor: Service and Repair Rear Door Rear Door Window Regulator Motor In the event of a window regulator motor failure with the glass in a down position such that the bottom of the glass is below the motor and drum housing, the regulator cannot be serviced as outlined in the previous procedure. 1. Disconnect battery ground cable. NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. Remove door trim panel and watershield. 3. Disconnect power window motor wire from wire harness connector. 4. Remove three rivets securing motor assembly to inner panel. 5. Align motor screws (square drive, tapered screws) with holes in inner panel and remove three screws. 6. Remove motor bracket from door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 7083 7. Using a screwdriver, pry housing and drum off of the motor. 8. Remove motor and pull glass to upper position to allow for more working room. CAUTION: Glass may move downward suddenly and quickly. Make sure glass will stay in upper position. Installation 1. Install new motor onto housing and drum. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 7084 2. Start the lower screw on motor first, but do not tighten. Leave approximately one-quarter inch between screw head and motor. 3. Slide motor bracket onto motor and the lower screw. 4. Align holes in motor with bracket and install remaining two screws. Tighten all three screws. 5. Align bracket with inner panel and install rivets. 6. Connect motor wiring, and battery ground cable. 7. Check window operation. 8. Install watershield and trim panel. Window Operational NOTE: If power window motor fails with glass in down position, refer to the next procedure, Rear Door Window Regulator Motor Replacement. Removal 1. Disconnect battery ground cable. 2. Remove door trim panel and watershield. See: Body and Frame/Doors, Hood and Trunk/Doors 3. Disconnect power window motor wire from wire harness connector. 4. Remove three 1/4-inch rivets attaching the motor bracket to inner panel. Use drift pin to knock out the center pins from each rivet. Using a 1/4-inch diameter drill, drill out the remainder of the rivet. Use care not to enlarge sheet metal holes in the door inner panel. 5. Working through access holes, remove motor attaching screws and separate motor from bracket and cable drum housing. 6. Remove motor from inside door. Installation 1. Position the motor and drive to cable drum housing and motor mounting bracket and install three motor screws. Tighten to 2.82-5.65 N-m (25-50 in-lb). 2. Connect power window motor wiring and battery ground cable. 3. Check window operation, install watershield, door trim panel, and armrest. See: Body and Frame/Doors, Hood and Trunk/Doors With Window Down and Inoperable NOTE: If power window motor fails with glass in down position, refer to the next procedure, Rear Door Window Regulator Motor Replacement. Removal 1. Disconnect battery ground cable. 2. Remove door trim panel and watershield. See: Body and Frame/Doors, Hood and Trunk/Doors 3. Disconnect power window motor wire from wire harness connector. 4. Remove three 1/4-inch rivets attaching the motor bracket to inner panel. Use drift pin to knock out the center pins from each rivet. Using a 1/4-inch diameter drill, drill out the remainder of the rivet. Use care not to enlarge sheet metal holes in the door inner panel. 5. Working through access holes, remove motor attaching screws and separate motor from bracket and cable drum housing. 6. Remove motor from inside door. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Front Door > Page 7085 Installation 1. Position the motor and drive to cable drum housing and motor mounting bracket and install three motor screws. Tighten to 2.82-5.65 N-m (25-50 in-lb). 2. Disconnect power window motor wiring and battery ground cable. 3. Check window operation, install watershield, door trim panel, and armrest. See: Body and Frame/Doors, Hood and Trunk/Doors Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views Power Window Switch: Locations Behind Instrument Panel Views All Except Limited Edition And Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7090 Component Locations Limited Edition And Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7091 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7092 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7093 Power Window Switch: Locations Full Body Views All Except Limited Edition and Electronic Group Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7094 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7095 Component Locations Limited Edition and Electronic Group Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7096 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Behind Instrument Panel Views > Page 7097 Component Locations Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7100 Sample Power Distribution Diagram Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7101 Sample System Diagram System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7102 Management, Radio/Stereo, etc. Sample Grounds Diagram Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads. The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution. Symbol Identification Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7103 ELECTRICAL SYMBOLS Electrical Symbols Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7104 Electrical Symbols VACUUM SYMBOLS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 Symbol Identification/Vacuum Symbols Wire Color Code Identification BK: Black BL: Blue BR: Brown DB: Dark Blue DG: Dark Green GY: Gray GN: Green LB: Light Blue Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 LG: Light Green PK: Pink O: Orange P: Purple R: Red T: Tan V: Violet W: White Y: Yellow NOTE: Where two colors are shown for a wire, first is basic color and second is stripe marking (tracer). For example, BR/O is brown with orange stripe. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 Power Window Switch: Connector Views Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Master Window Control Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 Power Window Switch: Electrical Diagrams Power Windows (2 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 Power Windows (4 Door) Limited Edition and Electronic Group Only Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 Power Windows (4 Door) Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film Window Glass: Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film > Page 7119 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film > Page 7120 Window Glass: Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film Windshield: Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Windshield/Interior Glass - Fog/Film > Page 7125 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Circuit Breaker, Wiper/Washer > Component Information > Testing and Inspection Circuit Breaker: Testing and Inspection NOTE: The 6 amp circuit breaker is located in the fuse panel. Two separate tests are necessary to check the circuit breaker for proper operation. Before performing these tests, remove the circuit breaker from the fuse panel and connect the tester leads to the circuit breaker. Test 1 1. Short tester leads together and adjust current draw until it equals circuit breaker rating. 2. Connect circuit breaker to tester. 3. Leave circuit breaker connected to tester for 10 minutes, holding current reading on tester at rated current. If circuit breaker opens before 10 minutes have elapsed, replace circuit breaker. Test 2 1. Short tester leads together and adjust current draw until it is twice the rated current. 2. Connect circuit breaker to tester, holding current reading on tester at twice the rated current. 3. If tester reading does not drop to zero within 30 seconds, replace circuit breaker. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch > Page 7135 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7136 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch > Page 7141 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test Wiper Switch: Testing and Inspection Continuity Test Fig. 6 Wiper Switch Continuity Test. Except 88 Bronco II & Ranger 1. Check continuity between switch terminals. 2. To detect marginal operation of switch, move switch lever while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test > Page 7144 Wiper Switch: Testing and Inspection Wiper, Washer Interval Test Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch Wiper Switch: Service and Repair Multifunction Switch REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch > Page 7147 Wiper Switch: Service and Repair Rear Wiper Switch 1. Disconnect battery ground cable, then remove ashtray and instrument cluster trim panel. 2. Remove switch mounting bezel containing switches, then disconnect switch electrical connector and remove switch. 3. Reverse procedure to install, checking wiper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Liftgate Washer Motor Windshield Washer Motor: Locations Liftgate Washer Motor Component Locations The Liftgate Washer Pump Motor is located in liftgate washer reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Liftgate Washer Motor > Page 7152 Windshield Washer Motor: Locations Windshield Washer Motor Component Locations The Washer Pump Motor is located in washer reservoir. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Interval Wiper/Washer Switch > Page 7157 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 7158 Windshield Washer Switch: Testing and Inspection Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations Wiper Motor: Locations All Except Limited Edition And Electronic Group The Wiper Motor is located at left of center, at rear of engine compartment. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7162 Wiper Motor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Page 7163 Wiper Motor: Testing and Inspection 1. Disconnect positive battery cable. 2. Disconnect linkage from motor and the electrical connector. Fig. 3 Wiper Motor Current Draw Test. Except Aerostar 3. Connect green lead from multimeter to battery negative post. 4. Connect positive lead of tester first to low speed connection and then to high speed connection at electrical connector. Current draw should not exceed 3 amps and the motor should run smoothly. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor Wiper Motor: Service and Repair Front Wiper Motor REMOVAL 1. Cycle windshield wipers until they are in straight up position, then turn ignition switch to OFF position. 2. Disconnect battery ground cable, then the wiper motor electrical connector. 3. Remove righthand wiper arm and blade assembly, then the righthand pivot nut and allow linkage to drop into cowl. 4. Remove linkage access cover from righthand side of dash panel. 5. Release wiper motor retaining clip, then slide clip back until it clears nib on crank pin, and remove the clip. NOTE: The wiper motor retaining clip can be reached through the access cover opening. 6. Remove wiper linkage from motor crank pin. 7. Remove motor attaching screws and the motor. INSTALLATION 1. Install wiper motor and torque attaching screws to 10-14 ft lb. 2. Connect wiper motor electrical connector, then install clip onto righthand linkage, ensure clip is fully seated. NOTE: Do not install linkage on motor crank pin, then attempt to install clip. 3. Install lefthand linkage onto motor crank pin, then the righthand linkage onto crank pin, pulling linkage onto pin until it snaps into place. NOTE: Clip is properly installed if nib is protruding through center of clip. 4. Install righthand wiper pivot shaft and nut and torque to 7-10 ft lb. 5. Connect battery ground cable, turn ignition switch to ON position, turn wiper switch OFF so wiper motor will PARK, then turn ignition switch to OFF position. 6. Install righthand linkage access cover, then the righthand wiper blade and arm assembly and check for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor > Page 7166 Wiper Motor: Service and Repair Rear Wiper Motor REMOVAL 1. Disconnect battery ground cable, then remove wiper arm and blade assembly. 2. Remove liftgate inner trim panel, then the motor bracket attaching screw. 3. Pull motor assembly out of rubber grommet, disconnect motor electrical connector and disengage wiring locator pins, then remove motor assembly. INSTALLATION 1. Position motor in liftgate rubber grommet and install attaching screws. 2. Connect motor electrical connector and install wiring locator pins. 3. Install wiper arm and blade assembly, then connect battery ground cable, and check for proper operation of wiper. 4. Install liftgate inner trim panel. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Cycle windshield wipers until they are in straight up position, then turn ignition switch to OFF position. 2. Disconnect battery ground cable, then the wiper motor electrical connector. 3. Remove righthand wiper arm and blade assembly, then the righthand pivot nut and allow linkage to drop into cowl. 4. Remove linkage access cover from righthand side of dash panel. 5. Release wiper motor retaining clip, then slide clip back until it clears nib on crank pin, and remove the clip. NOTE: The wiper motor retaining clip can be reached through the access cover opening. 6. Remove wiper linkage from motor crank pin. 7. Slide righthand pivot shaft and linkage assembly out through righthand access cover opening. 8. Remove lefthand wiper arm and blade assembly. 9. Remove lefthand linkage access cover and pivot nut, then lower linkage and slide out through access cover opening. NOTE: Lefthand and righthand pivot and linkage assemblies are serviced separately. INSTALLATION 1. Install clip onto lefthand linkage, ensure clip is fully seated. NOTE: Do not install linkage on motor crank pin, then attempt to install clip. 2. Slide lefthand pivot shaft and linkage assembly through lefthand access opening, positioning pivot shaft in place. 3. Install lefthand pivot shaft nut and torque to 7-10 ft lb. 4. Install lefthand linkage cover. 5. Slide righthand pivot shaft and linkage assembly through righthand access opening, positioning pivot shaft in place. 6. Connect wiper motor electrical connector, then install clip onto righthand linkage, ensure clip is fully seated. 7. Install lefthand linkage onto motor crank pin, then the righthand linkage onto crank pin, pulling linkage onto pin until it snaps into place. NOTE: Clip is properly installed if nib is protruding through center of clip. 8. Install righthand wiper pivot shaft and nut and torque to 7-10 ft lb. 9. Connect battery ground cable, turn ignition switch to ON position, turn wiper switch OFF so wiper motor will PARK, then turn ignition switch to OFF position. 10. Install righthand linkage access cover, then the right and lefthand wiper blade and arm assemblies and check for proper operation. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams Interval Windshield Wiper (IWW) Governor Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise Wiper Pivot: Customer Interest Blower Motor - Burning Odor/Smoke/Rustling Noise Article No. 99-20-6 10/04/99 ^ AIR CONDITIONING - BURNING ODOR OR SMOKE WHILE BLOWER MOTOR IS ON ^ NOISE - "RUSTLING" HEARD ALONG WITH AN ODOR WHILE BLOWER MOTOR IS ON FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER This TSB article is being republished in its entirety to change the Causal Part number. ISSUE A burning odor or smoke, and/or "rustling" noise may occur when the blower motor is running if leaves or foreign material enter the blower case. Noise complaints may result from debris coming in contact with the blower fan. In some cases, the debris may also come in contact with the blower motor resistor which may be hot enough to cause a burning odor or smoke. ACTION Clean the debris out of the blower case and install foam grommets around the wiper pivots to seal out further debris from entering the system. Refer to the following Service Procedure for details. SERVICE PROCEDURE ALL MODEL YEARS - CLEAN DEBRIS FROM THE HEATER CASE 1. Remove blower motor (refer to the appropriate Service or Workshop Manual for procedure). 2. Remove blower motor resistor. NOTE BE CAREFUL NOT TO DAMAGE OR BEND RESISTOR COILS WHICH COULD RESULT IN AN ELECTRICAL SHORT. 3. Clean the blower motor, motor cooling tube, blower housing, resistor, and inlet duct of all debris. 4. Reinstall resistor. 5. Reinstall blower motor. 1991-1994 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 7181 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > Customer Interest for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 7182 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise Wiper Pivot: All Technical Service Bulletins Blower Motor - Burning Odor/Smoke/Rustling Noise Article No. 99-20-6 10/04/99 ^ AIR CONDITIONING - BURNING ODOR OR SMOKE WHILE BLOWER MOTOR IS ON ^ NOISE - "RUSTLING" HEARD ALONG WITH AN ODOR WHILE BLOWER MOTOR IS ON FORD: 1991-1999 EXPLORER MERCURY: 1997-1999 MOUNTAINEER This TSB article is being republished in its entirety to change the Causal Part number. ISSUE A burning odor or smoke, and/or "rustling" noise may occur when the blower motor is running if leaves or foreign material enter the blower case. Noise complaints may result from debris coming in contact with the blower fan. In some cases, the debris may also come in contact with the blower motor resistor which may be hot enough to cause a burning odor or smoke. ACTION Clean the debris out of the blower case and install foam grommets around the wiper pivots to seal out further debris from entering the system. Refer to the following Service Procedure for details. SERVICE PROCEDURE ALL MODEL YEARS - CLEAN DEBRIS FROM THE HEATER CASE 1. Remove blower motor (refer to the appropriate Service or Workshop Manual for procedure). 2. Remove blower motor resistor. NOTE BE CAREFUL NOT TO DAMAGE OR BEND RESISTOR COILS WHICH COULD RESULT IN AN ELECTRICAL SHORT. 3. Clean the blower motor, motor cooling tube, blower housing, resistor, and inlet duct of all debris. 4. Reinstall resistor. 5. Reinstall blower motor. 1991-1994 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 7188 Refer to Figure 1 for grommet installation. 1. Remove the wiper arms from the splined shafts. 2. Place a beveled Grommet (XL2Z-78021A32-BA) with the offset hole, around each wiper shaft. Place the smooth side of the grommet facing up and the thin portion toward the windshield. Using the handle of a plastic knife, spoon or similar object, tuck the foam grommets under the sheet metal all the way around the shaft. When properly placed, the grommet should seal to the sheet metal. 3. Install the wiper arms on the shafts in their proper position relative to the windshield. 1995-1999 MODELS YEARS - INSTALL FOAM GROMMETS AROUND WIPER PIVOTS 1. Remove the wiper arms from the splined pivot shafts. 2. Remove the two-piece (left/right) plastic cowl grille by removing the one (1) screw in the center of the grille and then pulling on the grille to unseat the clips. 3. Place the round symmetrical Grommets (XL2Z-78021A32-AA) around the wiper shafts. 4. Replace the cowl grille by resetting the clips and installing the screw. 5. Install the wiper arms on the shafts in their proper position relative to the windshield. PART NUMBER PART NAME XL2Z-7802132-BA Grommet (Beveled) XL2Z-78021A32-AA Grommet (Symmetrical) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-15-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992006A Clean Debris From Heater 0.8 Hr. Case And Install Grommets DEALER CODING CONDITION Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Pivot: > 99-20-6 > Oct > 99 > Blower Motor - Burning Odor/Smoke/Rustling Noise > Page 7189 BASIC PART NO CODE 19805 49 OASIS CODES: 208000, 208999, 702000, 702300 Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch Interval Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Interval Windshield Wiper Switch > Page 7194 Liftgate Wiper/Washer Switch Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test Wiper Switch: Testing and Inspection Continuity Test Fig. 6 Wiper Switch Continuity Test. Except 88 Bronco II & Ranger 1. Check continuity between switch terminals. 2. To detect marginal operation of switch, move switch lever while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Continuity Test > Page 7197 Wiper Switch: Testing and Inspection Wiper, Washer Interval Test Component Testing Procedure Terminal ID Schematic Ford Explorer 2wd Workshop Manual (V6-245 4.0L (1994)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch Wiper Switch: Service and Repair Multifunction Switch REMOVAL 1. Disconnect battery ground cable. 2. On models with tilt steering, remove tilt lever, then the steering column collar by pressing on collar from top and bottom while removing. 3. On all models, remove lower dash panel trim cover, then the column shroud retaining screws from bottom of column shroud. 4. Remove bottom half of shroud by pulling shroud down and toward rear of vehicle. Move shift lever as required to ease shroud removal on models with automatic transmission. 5. Lift top half of shroud from column. 6. Remove two switch attaching screws, then disconnect switch from casting. 7. Disconnect three electrical connectors, using care not to damage locking tabs. Use care not to damage selector indicator cable on models with automatic transmission. INSTALLATION 1. Install three electrical connectors, ensure they are fully engaged. On models with automatic transmission, route wiring for switch under selector indicator cable. 2. Align switch mounting holes with holes in steering column casting, then install screws and torque to 18-27 inch lbs. 3. On models with automatic transmission, ensure selector indicator is adjusted properly. 4. On all models, position top half of steering column shroud onto column so that screw moldings on shroud seat in mounting bores in column. Place shift lever in its lowest position to aid assembly on vehicles with automatic transmission. 5. Install bottom half of shroud by sliding guides in bottom half of shroud into tabs in top half. 6. Install shroud retaining screws and torque to 18.5-25.6 inch lbs. 7. On models with tilt steering, proceed as follows: a. Install steering column collar by pressing on top and bottom while installing on column. b. Install tilt lever and torque to 2.2-3.6 ft lb. 8. On all models, install lower dash panel trim cover, then connect battery ground cable. 9. Check multi-function switch and steering column for correct operation.